U.S. patent application number 12/393197 was filed with the patent office on 2009-09-03 for touch screen sensor with low visibility conductors.
This patent application is currently assigned to 3M Innovative Properties Company. Invention is credited to Bernard O. GEAGHAN, Edward S. Hagermoser.
Application Number | 20090219258 12/393197 |
Document ID | / |
Family ID | 51211948 |
Filed Date | 2009-09-03 |
United States Patent
Application |
20090219258 |
Kind Code |
A1 |
GEAGHAN; Bernard O. ; et
al. |
September 3, 2009 |
TOUCH SCREEN SENSOR WITH LOW VISIBILITY CONDUCTORS
Abstract
A touch screen sensor with a conductive micropattern includes
one or more features to obscure or reduce the visibility of the
conductive micropattern.
Inventors: |
GEAGHAN; Bernard O.; (Salem,
NH) ; Hagermoser; Edward S.; (Lancaster, MA) |
Correspondence
Address: |
3M INNOVATIVE PROPERTIES COMPANY
PO BOX 33427
ST. PAUL
MN
55133-3427
US
|
Assignee: |
3M Innovative Properties
Company
|
Family ID: |
51211948 |
Appl. No.: |
12/393197 |
Filed: |
February 26, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61032269 |
Feb 28, 2008 |
|
|
|
61032273 |
Feb 28, 2008 |
|
|
|
61085496 |
Aug 1, 2008 |
|
|
|
61085799 |
Aug 1, 2008 |
|
|
|
61085764 |
Aug 1, 2008 |
|
|
|
Current U.S.
Class: |
345/173 |
Current CPC
Class: |
C23F 1/14 20130101; G06F
3/045 20130101; G06F 2203/04112 20130101; G06F 3/0446 20190501;
G06F 3/0445 20190501; G06F 3/0412 20130101 |
Class at
Publication: |
345/173 |
International
Class: |
G06F 3/041 20060101
G06F003/041 |
Claims
1. A touch-sensitive device comprising: a first visible light
transparent substrate having a touch-interface surface and a
display-interface surface, the touch-interface surface disposed
toward touch input, and the display interface disposed toward the
output of a display; a second visible light transparent substrate
having a first surface and a second surface and also having a touch
sensing area comprised of an electrically conductive micropattern
disposed on or in the second visible light transparent substrate,
wherein the micropattern includes conductors with width between
about 1 and 10 micrometers; wherein the first surface of the second
visible light transparent substrate is disposed toward the
display-interface surface of the first visible light transparent
substrate; and wherein the first visible light transparent
substrate includes a feature that reduces the visibility of the
micropattern.
2. The touch-sensitive device of claim 1, wherein the feature
comprises an anti-glare or matte finish.
3. The touch-sensitive device of claim 1, wherein the display is a
liquid crystal display or an organic light emitting diode
display.
4. The touch-sensitive device of claim 3, wherein the feature
comprises a linear polarizer.
5. The touch-sensitive device of claim 3, wherein the feature
comprises a circular polarizer.
6. The touch-sensitive device of claim 3, wherein the feature
comprises a contrast filter having light transmission of between
40% and 90%.
7. The touch-sensitive device of claim 3, wherein the feature
comprises light scattering elements.
8. The touch-sensitive device of claim 7, wherein the diffuser
elements comprise randomly or pseudo-randomly oriented facets.
9. The touch-sensitive device of claim 8, wherein the facets have a
size greater than the width of the conductors.
10. The touch-sensitive device of claim 7, wherein the scattering
elements comprise bumps.
11. A touch screen sensor comprising: within a touch sensing area,
a electrically conductive micropattern disposed on or in a visible
light transparent substrate, wherein the micropattern includes
conductive traces with width between about 1 and 10 micrometers;
and one or more micropattern-obscuring features to reduce the
visibility of the micropattern.
12. The touch screen sensor of claim 11, wherein the
micropattern-obscuring features are within a substrate other than
the visible light transparent substrate.
13. The touch screen sensor of claim 11, wherein at least one of
the micropattern-obscuring features comprises a linear
polarizer.
14. The touch screen sensor of claim 11, wherein at least one of
the micropattern-obscuring features comprises a circular
polarizer.
15. The touch screen sensor of claim 11, wherein at least one of
the micropattern-obscuring features comprises a contrast filter
having light transmission of between 40% and 90%.
16. The touch screen sensor of claim 11, wherein at least one of
the micropattern-obscuring features comprises one ore more light
scattering elements.
17. The touch screen sensor of claim 16, wherein the scattering
elements comprise randomly or pseudo-randomly oriented facets.
18. The touch screen sensor of claim 16, wherein the facets have a
size greater than the width of the conductive traces.
19. The touch screen sensor of claim 16, wherein the scattering
elements comprises bumps.
20. The touch screen sensor of claim 11, wherein the touch sensing
area is visible light transparent and having between 90% and 99.95%
open area.
21. The touch screen sensor of claim 11, wherein the micropattern
obscuring feature comprises an anti-glare or matte finish.
22. The touch screen sensor of claim 11, wherein the micropattern
obscuring feature comprises pseudo-random variations in the
micropattern.
23. The touch screen sensor of claim 11, wherein the electrically
conductive micropattern is a touch sensitive electrically
conductive micropattern.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Nos. 61/032,269, filed Feb. 28, 2008, the disclosure of
which is incorporated by reference herein in its entirety;
61/032,273, filed Feb. 28, 2008, the disclosure of which is
incorporated by reference herein in its entirety; 61/085,496, filed
Aug. 1, 2008, the disclosure of which is incorporated by reference
herein in its entirety; 61/085,799, filed Aug. 1, 2008, the
disclosure of which is incorporated by reference herein in its
entirety; and 61/085,764, filed Aug. 1, 2008, the disclosure of
which is incorporated by reference herein in its entirety.
BACKGROUND
[0002] Touch screen sensors detect the location of an object (e.g.
a finger or a stylus) applied to the surface of a touch screen
display or the location of an object positioned near the surface of
a touch screen display. These sensors detect the location of the
object along the surface of the display, e.g. in the plane of a
flat rectangular display. Examples of touch screen sensors include
capacitive sensors, resistive sensors, and projected capacitive
sensors. Such sensors include transparent conductive elements that
overlay the display. The elements are combined with electronic
components that use electrical signals to probe the elements in
order to determine the location of an object near or in contact
with the display.
[0003] In the field of touch screen sensors, there is a need to
have improved control over the electrical properties of the
transparent touch screen sensors, without compromising optical
quality or properties of the display. A transparent conductive
region of a typical touch screen sensor includes a continuous
coating of a transparent conducting oxide (TCO) such as indium tin
oxide (ITO), the coating exhibiting electrical potential gradients
based on the location or locations of contact to a voltage source
and the overall shape of the region. This fact leads to a
constraint on possible touch sensor designs and sensor performance,
and necessitates such measures as expensive signal processing
electronics or placement of additional electrodes to modify the
electrical potential gradients. Thus, there is a need for
transparent conductive elements that offer control over electrical
potential gradients that is independent of the aforementioned
factors.
BRIEF SUMMARY
[0004] A touch sensor or touch sensitive device having features to
obscure or reduce the visibility of conductive micropattern
elements.
[0005] In one embodiment, a touch-sensitive device is described,
the touch sensitive device comprising a first visible light
transparent substrate having a touch-interface surface and a
display-interface surface, the touch-interface surface disposed
toward touch input, and the display interface disposed toward the
output of a display; a second visible light transparent substrate
having a first surface and a second surface and also having a touch
sensing area comprised of an electrically conductive micropattern
disposed on or in the second visible light transparent substrate,
wherein the micropattern includes conductors with width between
about 1 and 10 micrometers; wherein the first surface of the second
visible light transparent substrate is disposed toward the
display-interface surface of the first visible light transparent
substrate; and wherein the first visible light transparent
substrate includes a feature that reduces the visibility of the
micropattern.
[0006] In another embodiment, a touch screen sensor is described,
the touch screen sensor comprising, within a touch sensing area, a
electrically conductive micropattern disposed on or in a visible
light transparent substrate, wherein the micropattern includes
conductive traces with width between about 1 and 10 micrometers;
one or more micropattern-obscuring features to reduce the
visibility of the micropattern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention may be more completely understood in
consideration of the following detailed description of various
embodiments of the invention in connection with the accompanying
drawings, in which:
[0008] FIG. 1 illustrates a schematic diagram of a touch screen
sensor 100;
[0009] FIG. 2 illustrates a perspective view of a conductive
visible light transparent region lying within a touch screen
sensing area;
[0010] FIG. 3 illustrates a process for creating microconductors
using UV laser curing of a conductive ink;
[0011] FIG. 4 illustrates a gravure printing process for creating
microconductors;
[0012] FIG. 5 illustrates a cross section view of microreplicated
channels filled with conductive material;
[0013] FIG. 6 illustrates a finger capacitively coupling with
microreplicated channels filled with conductive material;
[0014] FIG. 7 illustrates patterns of microconductors produced on a
flexible substrate, useful for producing touch sensors;
[0015] FIG. 8 illustrates parallel microconductors printed on a
flexible web material in the downweb direction;
[0016] FIG. 9 illustrates a section of the flexible material from
FIG. 8 having additional interconnecting conductors added;
[0017] FIG. 10 illustrates a cross section of an example of a
matrix touch sensor constructed from two layers of the materials
from FIG. 9;
[0018] FIG. 11 illustrates the conductor micropattern for one
embodiment of the touch screen sensor;
[0019] FIG. 12 illustrates a portion of the conductor micropattern
illustrated in FIG. 3, the portion including a conductive mesh with
selective breaks for modulating the local sheet resistance as well
as a larger feature in the form of a contact pad;
[0020] FIG. 13 illustrates a modulation in resistance along the
horizontal mesh bars given in FIG. 3, created by selective breaks
in the contiguous mesh;
[0021] FIG. 14 is a circuit diagram that approximates the
properties of the conductor micropattern illustrated in FIG. 3,
where capacitive plates are separated by resistive elements;
[0022] FIG. 15 illustrates the conductor micropattern for one
embodiment of the touch screen sensor, the micropattern including
regions labeled 15a -15e with different sheet resistance created in
part by selective breaks in the electrically conductive
micropattern mesh;
[0023] FIGS. 15a -15e each illustrate a portion of the varying
conductor micropattern illustrated in FIG. 15;
[0024] FIG. 16 illustrates the distribution of resistance per unit
length along the long axis of the wedge-shaped transparent
conductive region having regions 15a and 15b therein, as compared
with the resistance per unit length for a similarly shaped region
comprising only a uniform transparent conducting oxide, ITO;
[0025] FIG. 17 illustrates the arrangement of layers that are
laminated together to form one embodiment of the touch screen
sensor, an X-Y grid type projected capacitive touch screen
sensor;
[0026] FIG. 18 illustrates the conductor micropattern for the
X-layer or the Y-layer of an embodiment of the touch screen sensor
according to FIG. 17;
[0027] FIG. 19 illustrates a portion of the conductor micropattern
illustrated in FIG. 10, the portion including a visible light
transparent conductive mesh contacting a larger feature in the form
of a contact pad, as well as electrically isolated conductor
deposits in the space between the mesh regions;
[0028] FIG. 20 illustrates the conductor micropattern for the
X-layer or the Y-layer of another embodiment of the touch screen
sensor according to FIG. 9;
[0029] FIG. 21 illustrates a portion of the conductor micropattern
given in FIG. 12, the portion including a visible light transparent
conductive mesh contacting a larger feature in the form of a
contact pad, as well as electrically isolated conductor deposits in
the space between the mesh regions;
[0030] FIG. 22 illustrates the conductor micropattern for the
X-layer or the Y-layer of another embodiment of the touch screen
sensor according to FIG. 17; and
[0031] FIG. 23 illustrates a portion of the conductor micropattern
given in FIG. 22, the portion including a visible light transparent
conductive mesh contacting a larger feature in the form of a
contact pad, as well as electrically isolated conductor deposits in
the space between the mesh regions.
[0032] FIG. 24 illustrates a graph to reflect optical quality of
the touch screen sensor, the graph being a plot of Percent of Open
Area vs. conductor trace width (in micrometers), with Region 3
being good optical quality that can be used for a touch screen
sensor, Region 2 being better in optical quality as compared to
Region 2, and Region 1 having the best optical quality of the three
regions. Percent of Open Area is used interchangeably with open
area fraction herein.
[0033] FIG. 25 and FIG. 26 illustrate scanning electron
photomicrographs of the geometry for the hexagonal mesh (sometimes
referred to as "hex" mesh) and square mesh that are characteristic
of Examples 6 through 40. The light shade lines in each image
represent the pattern of the metal conductor and the dark area
represents the substrate used in the Examples.
[0034] FIGS. 27, 27a, and 27b illustrate various portions of a
first patterned substrate;
[0035] FIGS. 28, 28a, and 28b illustrate various portions of a
second patterned substrate;
[0036] FIG. 29 illustrates a projected capacitive touch screen
transparent sensor element constructed from the first and second
patterned substrates of FIGS. 27 and 28.
[0037] FIG. 30 illustrates a perspective view of a conductive
visible light transparent region lying within a touch screen
sensing area;
[0038] FIG. 31 illustrates a micropattern obscuring feature
positioned between a finger and a micropatterned
microconductor.
[0039] The figures are not necessarily to scale. Like numbers used
in the figures refer to like components. However, it will be
understood that the use of a number to refer to a component in a
given figure is not intended to limit the component in another
figure labeled with the same number.
DETAILED DESCRIPTION
[0040] In the following description, reference is made to the
accompanying set of drawings that form a part hereof and in which
are shown by way of illustration several specific embodiments. It
is to be understood that other embodiments are contemplated and may
be made without departing from the scope or spirit of the present
invention. The following detailed description, therefore, is not to
be taken in a limiting sense.
[0041] All scientific and technical terms used herein have meanings
commonly used in the art unless otherwise specified. The
definitions provided herein are to facilitate understanding of
certain terms used frequently herein and are not meant to limit the
scope of the present disclosure.
[0042] Unless otherwise indicated, all numbers expressing feature
sizes, amounts, and physical properties used in the specification
and claims are to be understood as being modified in all instances
by the term "about." Accordingly, unless indicated to the contrary,
the numerical parameters set forth in the foregoing specification
and attached claims are approximations that can vary depending upon
the desired properties sought to be obtained by those skilled in
the art utilizing the teachings disclosed herein.
[0043] The recitation of numerical ranges by endpoints includes all
numbers within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3,
3.80, 4, and 5) and any range within that range.
[0044] As used in this specification and the appended claims, the
singular forms "a", "an", and "the" encompass embodiments having
plural referents, unless the context clearly dictates otherwise. As
used in this specification and the appended claims, the term "or"
is generally employed in its sense including "and/or" unless the
context clearly dictates otherwise.
[0045] As used herein, "visible light transparent" refers to the
level of transmission being at least 60 percent transmissive to at
least one polarization state of visible light, where the percent
transmission is normalized to the intensity of the incident,
optionally polarized light. It is within the meaning of visible
light transparent for an article that transmits at least 60 percent
of incident light to include microscopic features (e.g., dots,
squares, or lines with minimum dimension, e.g. width, between 0.5
and 10 micrometers, or between 1 and 5 micrometers) that block
light locally to less than 80 percent transmission (e.g., 0
percent); however, in such cases, for an approximately equiaxed
area including the microscopic feature and measuring 1000 times the
minimum dimension of the microscopic feature in width, the average
transmittance is greater than 60 percent.
[0046] The present disclosure relates to touch screen sensors with
electrical and optical properties that are engineered through
design of conductor micropatterns comprised therein. There are
several advantages that are created for touch screen sensors by the
incorporation of the conductor micropatterns described herein. In
some embodiments, the transparent conductive properties within a
transparent conductive region are engineered to control the
electrical potential gradient within the touch sensing region
during use. This leads to simplicity of signal processing
electronics and, for some touch screen sensor types simplicity in
the design of (or elimination of the need for) additional conductor
patterns that would otherwise be needed for electrical potential
gradient (electrical field) linearization. In some embodiments, the
electrical properties of the touch screen sensors described herein
are designed to generate a controlled electrical potential gradient
along a transparent sensor element. E.g., the electrical properties
are designed to create a linear electrical potential gradient along
a particular direction within a transparent conductive region, the
overall shape of which would ordinarily lead to a non-linear
gradient if a standard transparent conductor material was used
(e.g., continuous ITO coating). In some embodiments, the electrical
properties are designed to create a level of non-linearity of
electrical potential gradient for a transparent conductive region
that is greater than that which would be present within a
transparent conductive region of the same shape but comprised of a
standard transparent conductor material (e.g., continuous ITO
coating). In more detail, for a rectangular capacitive touch screen
comprising a contiguous transparent sheet conductor in the form of
a micropatterned conductor with electrical connections made to the
corners of the sensing area, the linearity of electrical potential
gradient (and uniformity of electric field) across the sensing area
in the vertical and horizontal directions can be improved by
engineering the area distribution of sheet resistance values and
anisotropy in such a way as to distribute the field more uniformly.
In other embodiments, the sensor includes conductor elements
comprised of the same conductor material at the same thickness
(i.e., height), but with different effective sheet resistance by
virtue of micropatterning. E.g., in some embodiments, the same
conductor material at the same thickness (i.e., height) is used to
generate conductive traces that define a first micropattern
geometry, leading to a first level of sheet resistance in a
transparent conductive region, and conductive traces that define a
second micropattern geometry, leading to a second level of sheet
resistance in a second transparent conductive region. This
disclosure also allows for improved efficiency and resource
utilization in the manufacture of transparent display sensors, e.g.
through the avoidance of rare elements such as indium for some
embodiments, e.g. embodiments based on micropatterned metal
conductors.
[0047] The disclosure further relates to contact or proximity
sensors for touch input of information or instructions into
electronic devices (e.g., computers, cellular telephones, etc.)
These sensors are visible light transparent and useful in direct
combination with a display, overlaying a display element, and
interfaced with a device that drives the display (as a "touch
screen" sensor). The sensor element has a sheet like form and
includes at least one electrically insulating visible light
transparent substrate layer that supports one or more of the
following: i) conductive material (e.g., metal) that is mesh
patterned onto two different regions of the substrate surface with
two different mesh designs so as to generate two regions with
different effective sheet resistance values, where at least one of
the regions is a transparent conductive region that lies within the
touch-sensing area of the sensor; ii) conductive material (e.g.,
metal) that is patterned onto the surface of the substrate in a
mesh geometry so as to generate a transparent conductive region
that lies within the touch sensing area of the sensor and that
exhibits anisotropic effective sheet resistance; and/or iii)
conductive material (e.g., metal) that is patterned onto the
surface of the substrate in a mesh geometry within an effectively
electrically continuous transparent conductive region, the geometry
varying within the region so as to generate different values of
local effective sheet resistance in at least one direction (e.g.,
continuously varying sheet resistance for the transparent
conductive region), where the region lies within the sensing area
of the touch sensor.
[0048] The sensing area of a touch sensor is that region of the
sensor that is intended to overlay, or that overlays, a viewable
portion of an information display and is visible light transparent
in order to allow viewability of the information display. Viewable
portion of the information display refers to that portion of an
information display that has changeable information content, e.g.
the portion of a display "screen" that is occupied by pixels, e.g.
the pixels of a liquid crystal display.
[0049] This disclosure further relates to touch screen sensors that
are of the resistive, capacitive, and projected capacitive types.
The visible light transparent conductor micropatterns are
particularly useful for projected capacitive touch screen sensors
that are integrated with electronic displays. As a component of
projected capacitive touch screen sensors, the visible light
transparent conductive micropattern are useful for enabling high
touch sensitivity, multi-touch detection, and stylus input.
[0050] The two or more different levels of sheet resistance, the
anisotropy of the sheet resistance, or the varying level of sheet
resistance within a transparent conductive region can be controlled
by the geometries of two-dimensional meshes that make up the
transparent micropatterned conductors, as described below.
[0051] While the present invention is not so limited, an
appreciation of various aspects of the invention will be gained
through a discussion of the examples provided below.
[0052] FIG. 1 illustrates a schematic diagram of a touch screen
sensor 100. The touch screen sensor 100 includes a touch screen
panel 110 having a touch sensing area 105. The touch sensing area
105 is electrically coupled to a touch sensor drive device 120. The
touch screen panel 110 is incorporated into a display device.
[0053] FIG. 2 illustrates a perspective view of a conductive
visible light transparent region 101 that would lie within a touch
sensing area of a touch screen panel, e.g., touch sensing area 105
in FIG. 1. The conductive visible light transparent region 101
includes a visible light transparent substrate 130 and an
electrically conductive micropattern 140 disposed on or in the
visible light transparent substrate 130. The visible light
transparent substrate 130 includes a major surface 132 and is
electrically insulating. The visible light transparent substrate
130 can be formed of any useful electrically insulating material
such as, e.g., glass or polymer. Examples of useful polymers for
light transparent substrate 130 include polyethylene terephthalate
(PET) and polyethylene naphthalate (PEN). The electrically
conductive micropattern 140 can be formed of a plurality of linear
metallic features.
[0054] FIG. 2 also illustrates an axis system for use in describing
the conductive visible light transparent region 101 that would lie
within a touch sensing area of a touch screen panel. Generally, for
display devices, the x and y axes correspond to the width and
length of the display and the z axis is typically along the
thickness (i.e., height) direction of a display. This convention
will be used throughout, unless otherwise stated. In the axis
system of FIG. 2, the x axis and y axis are defined to be parallel
to a major surface 132 of the visible light transparent substrate
130 and may correspond to width and length directions of a square
or rectangular surface. The z axis is perpendicular to that major
surface and is typically along the thickness direction of the
visible light transparent substrate 130. A width of the plurality
of linear metallic features that form the electrically conductive
micropattern 140 correspond to an x-direction distance for the
parallel linear metallic features that extend linearly along the y
axis and a y-direction distance for the orthogonal linear metallic
features correspond to a width of the orthogonal linear metallic
features. A thickness or height of the linear metallic features
corresponds to a z-direction distance.
[0055] In some embodiments, the conductive visible light
transparent region 101 that would lie within a touch sensing area
of a touch screen panel includes two or more layers of visible
light transparent substrate 130 each having a conductive
micropattern 140.
[0056] The conductive micropattern 140 is deposited on the major
surface 132. Because the sensor is to be interfaced with a display
to form a touch screen display, or touch panel display, the
substrate 130 is visible light transparent and substantially
planar. The substrate and the sensor may be substantially planar
and flexible. By visible light transparent, what is meant is that
information (e.g., text, images, or figures) that is rendered by
the display can be viewed through the touch sensor. The viewability
and transparency can be achieved for touch sensors including
conductors in the form of a deposited metal, even metal that is
deposited with thickness great enough to block light, if the metal
is deposited in an appropriate micropattern.
[0057] The conductive micropattern 140 includes at least one
visible light transparent conductive region overlaying a viewable
portion of the display that renders information. By visible light
transparent conductive, what is meant is that the portion of the
display can be viewed through the region of conductive micropattern
and that the region of micropattern is electrically conductive in
the plane of the pattern, or stated differently, along the major
surface of the substrate onto which the conductive micropattern is
deposited and to which it is adjacent. Preferred conductive
micropatterns include regions with two dimensional meshes, e.g.
square grids, rectangular (non-square) grids, or regular hexagonal
networks, where conductive traces define enclosed open areas within
the mesh that are not deposited with conductor that is in
electrical contact with the traces of the mesh. The open spaces and
associated conductor traces at their edges are referred to herein
as cells. Other useful geometries for mesh cells include random
cell shapes and irregular polygons.
[0058] In some embodiments, the conductive traces defining the
conductive micropattern are designed not to include segments that
are approximately straight for a distance greater than the combined
edge length of five adjacent cells, preferably four adjacent cells,
more preferably three adjacent cells, even more preferably two
adjacent cells. Most preferably, the traces defining the
micropattern are designed not to include segments that are straight
for a distance greater than the edge length of a single cell.
Accordingly, in some embodiments, the traces that define the
micropattern are not straight over long distances, e.g., 10
centimeters, 1 centimeter, or even 1 millimeter. Patterns with
minimal lengths of straight line segments, as just described, are
particularly useful for touch screen sensors with the advantage of
causing minimal disturbance of display viewability.
[0059] The two-dimensional geometry of the conductive micropattern
(that is, geometry of the pattern in the plane or along the major
surface of the substrate) can be designed, with consideration of
the optical and electrical properties of the conductor material, to
achieve special transparent conductive properties that are useful
in touch screen sensors. E.g., whereas a continuous (un-patterned)
deposit or coating of conductor material has a sheet resistance
that is calculated as its bulk resistivity divided by its
thickness, in the present invention different levels of sheet
resistance are engineered by micropatterning the conductor as
well.
[0060] In some embodiments, the two-dimensional conductive
micropattern is designed to achieve anisotropic sheet resistance in
a conductive region (e.g., a visible light transparent conductive
region) of the sensor. By anisotropic sheet resistance, what is
meant is that the magnitude of the sheet resistance of the
conductive micropattern is different when measured or modeled along
two orthogonal directions.
[0061] In contrast, in some embodiments, the two-dimensional
conductive micropattern is designed to achieve isotropic sheet
resistance in a conductive region (e.g., a visible light
transparent conductive region) of the sensor. By isotropic sheet
resistance, what is meant is that the magnitude of the sheet
resistance of the conductive micropattern is the same when measured
or modeled along any two orthogonal directions in the plane, as in
the case for a square grid formed with traces of constant width for
both directions.
[0062] Anisotropic sheet resistance within a region can include
sheet resistance in one direction that is at least 10 percent
greater than the sheet resistance in the orthogonal direction, or
at least 25 percent greater, at least 50 percent greater, at least
100 percent greater, at least 200 percent greater, at least 500
percent greater, or even at least 10 times greater. In some
embodiments, anisotropic sheet resistance within a region includes
sheet resistance in one direction that is greater than the sheet
resistance in the orthogonal direction by a factor of at least 1.5.
In some embodiments, anisotropic sheet resistance within a region
includes sheet resistance in one direction that is greater than the
sheet resistance in the orthogonal direction by a factor between
1.1 and 10, in other embodiments between 1.25 and 5, and in yet
other embodiments between 1.5 and 2.
[0063] An example of a conductive micropattern geometry that can
generate anisotropic sheet resistance is approximately a
rectangular microgrid (non-square) with fixed widths for the
conductive traces. For such a rectangular microgrid (non-square),
anisotropic sheet resistance can result from a repeating geometry
for the cells of the grid that includes one edge that is 10 percent
longer than the other, 25 percent longer than the other, at least
50 percent longer than the other, 100 percent longer than the
other, or even 10 times longer than the other. Anisotropic sheet
resistance can be created by varying the width of traces for
different directions, e.g. in an otherwise highly symmetrical
pattern of cells for a mesh. An example of the latter approach to
generating anisotropic sheet resistance is a square grid of
conductive traces, e.g. with pitch of 200 micrometers, wherein the
traces in a first direction are 10 micrometers wide and the traces
in the orthogonal direction are 9 micrometers in width, 7.5
micrometers in width, 5 micrometers in width, or even 1 micrometer
in width. Anisotropic sheet resistance within a region can include
a finite, measurable sheet resistance in one direction and
essentially infinite sheet resistance in the other direction, as
would be generated by a pattern of parallel conductive lines. In
some embodiments, as described above, the anisotropic sheet
resistance within a region includes a finite, measurable sheet
resistance in a first direction and a finite, measurable sheet
resistance in the direction orthogonal to the first direction.
[0064] For the purpose of determining whether a region of
conductive micropattern is isotropic or anisotropic, it will be
appreciated by those skilled in the art that the scale of the
region of interest must be reasonably selected, relative to the
scale of the micropattern, to make relevant measurements or
calculations of properties. E.g., once a conductor is patterned at
all, it is trivial for one to select a location and a scale on
which to make a measurement that will yield a difference in sheet
resistance for different directions of measurement. The following
detailed example can make the point more clearly. If one considered
a conductor pattern of isotropic geometry in the form of a square
grid with 100 micrometer wide conductor traces and 1 millimeter
pitch (leading to 900 micrometer by 900 micrometer square openings
in the grid), and one made four point probe measurements of sheet
resistance within one of the traces along the edge of a square
opening with a probe having fixed spacing along the four linearly
arranged probes of 25 micrometers (leading to a separation between
the two current probes, the outside probes, of 75 micrometers),
different levels of sheet resistance will be calculated by the
measured values of current and voltage depending on whether the
probes were aligned parallel to the trace or orthogonal to the
trace. Thus, even though the square grid geometry would yield
isotropic sheet resistance on a scale larger than the square grid
cell size, it is possible for one to carry out measurements of
sheet resistance that would suggest anisotropy. Thus, for the
purpose of defining anisotropy of the sheet resistance of a
conductive micropattern in the current disclosure, e.g. a visible
light transparent conductive region of the micropattern that
comprises a mesh, the relevant scale over which the sheet
resistance should be measured or modeled is greater than the length
scale of a cell in the mesh, preferably greater than the length
scale of two cells. In some cases, the sheet resistance is measured
or modeled over the length scale of five or more cells in the mesh,
to show that the mesh is anisotropic in its sheet resistance.
[0065] In contrast to embodiments where the conductive micropattern
exhibits anisotropy of sheet resistance in a region, sensors
including transparent conducting oxide thin films (e.g., indium tin
oxide, or ITO) exhibit isotropic sheet resistance in contiguous
regions of the conductor. In the latter case, one can measure or
model that as four-point probe measurements of sheet resistance of
a contiguous region are made in different directions and with
decreasing spacing between the probes, the same readings of current
and voltage for different directions clearly indicate isotropy.
[0066] In some embodiments, the two-dimensional conductive
micropattern is designed to achieve different levels, or
magnitudes, of sheet resistance in two different patterned
conductor regions of the sensor, when measured in a given
direction. E.g., with respect to the different levels of sheet
resistance, the greater of the two may exceed the lesser by a
factor greater than 1.25, a factor greater than 1.5, a factor
greater than 2, a factor greater than 5, a factor greater than 10,
or even a factor greater than 100. In some embodiments, the greater
of the two sheet resistance values exceeds the lesser by a factor
between 1.25 and 1000, in other embodiments between 1.25 and 100,
in other embodiments between 1.25 and 10, in other embodiments
between 2 and 5. For a region to be regarded as having a different
sheet resistance from that of another region, it would have a sheet
resistance that is greater or lesser than that of the other region
by a factor of at least 1.1.
[0067] In some embodiments, the micropattern is designed to achieve
the aforementioned different levels of sheet resistance for two
patterned conductor regions that are electrically contiguous, which
is to say that they are patterned conductor regions that are in
electrical contact with each other along a boundary between them.
Each of the two patterned conductor regions that share a conductive
boundary may have uniform respective pattern geometries, but again
different. In some embodiments, the micropattern is designed to
achieve the different levels of sheet resistance for two different
patterned conductor regions that are electrically noncontiguous,
which is to say that the they are patterned conductor regions that
share no boundary between them for which the patterned regions are
in electrical contact along that boundary. Each of the two
patterned conductor regions that share no conductive boundary
between them may have uniform respective pattern geometries, but
again different. For electrically noncontiguous regions, it is
within the scope of the disclosure for them both to make electrical
contact in the pattern to the same solid conductor element, e.g. a
bus bar or pad. In some embodiments, the micropattern is designed
to achieve the different levels of sheet resistance for two regions
that are electrically isolated from each other and thus can be
addressed independently by electrical signals. Each of the two mesh
regions that are electrically isolated may have a uniform pattern
geometry, but again different. Finally, in some embodiments, the
micropattern is designed to achieve different levels of sheet
resistance for two different regions by creating continuously
varying sheet resistance from the first region to the second, and
example of two regions that are electrically contiguous.
[0068] The two dimensional conductive micropatterns that include
two regions with different sheet resistance in a measurement
direction are useful for designing a visible light transparent
conductive region in the sensing area with a preferred level of
sheet resistance for that region (e.g., low sheet resistance
between 5 and 100 ohms per square), including varying or
anisotropic sheet resistance optionally, and designing an
electrical element, e.g. a resistor element, as part of the touch
screen sensor that may or may not lie within the sensing area, the
resistor element comprising a sheet conductor with sheet resistance
selected optimally for the resistor function (e.g., higher sheet
resistance between 150 and 1000 ohms per square) and possibly in
light of other design constraints, e.g. the constraint of
minimizing the footprint of the resistor.
[0069] The sheet resistance of the conductive micropattern, in
regions and directions with finite sheet resistance that can be
measured or modeled, as described above, may fall within the range
of 0.01 ohms per square to 1 megaohm per square, or within the
range of 0.1 to 1000 ohms per square, or within the range of 1 to
500 ohms per square. In some embodiments, the sheet resistance of
the conductive micropattern falls within the range of 1 to 50 ohms
per square. In other embodiments, the sheet resistance of the
conductive micropattern falls within the range of 5 to 500 ohms per
square. In other embodiments, the sheet resistance of the
conductive micropattern falls within the range of 5 to 100 ohms per
square. In other embodiments, the sheet resistance of the
conductive micropattern falls within the range of 5 to 40 ohms per
square. In other embodiments, the sheet resistance of the
conductive micropattern falls within the range of 10 to 30 ohms per
square. In prescribing the sheet resistance that may characterize a
conductive micropattern or a region of a conductive micropattern,
the micropattern or region of micropattern is said to have a sheet
resistance of a given value if it has that sheet resistance value
for electrical conduction in any direction.
[0070] Appropriate micropatterns of conductor for achieving
transparency of the sensor and viewability of a display through the
sensor have certain attributes. First of all, regions of the
conductive micropattern through which the display is to be viewed
should have an area fraction of the sensor that is shadowed by the
conductor of less than 50%, or less than 25%, or less than 20%, or
less than 10%, or less than 5%, or less than 4%, or less than 3%,
or less than 2%, or less than 1%, or in a range from 0.25 to 0.75%,
or less than 0.5%.
[0071] The open area fraction (or open area or Percentage of Open
Area) of a conductive micropattern, or region of a conductive
micropattern, is the proportion of the micropattern area or region
area that is not shadowed by the conductor. The open area is equal
to one minus the area fraction that is shadowed by the conductor,
and may be expressed conveniently, and interchangeably, as a
decimal or a percentage. Area fraction that is shadowed by
conductor is used interchangeably with the density of lines for a
micropatterned conductor. Micropatterned conductor is used
interchangeably with electrically conductive micropattern and
conductive micropattern. Thus, for the values given in the above
paragraph for the fraction shadowed by conductor, the open area
values are greater than 50%, greater than 75%, greater than 80%,
greater than 90%, greater than 95%, greater than 96%, greater than
97%, greater than 98%, greater than 99%, 99.25 to 99.75%, 99.8%,
99.85%, 99.9% and even 99.95. In some embodiments, the open area of
a region of the conductor micropattern (e.g., a visible light
transparent conductive region) is between 80% and 99.5%, in other
embodiments between 90% and 99.5%, in other embodiments between 95%
and 99%, in other embodiments between 96% and 99.5%, in other
embodiments between 97% and 98%, and in other embodiments up to
99.95%. With respect to the reproducible achievement of useful
optical properties (e.g. high transmission and invisibility of
conductive pattern elements) and electrical properties, using
practical manufacturing methods, preferred values of open area are
between 90 and 99.5%, more preferably between 95 and 99.5%, most
preferably between 95 and 99.95%.
[0072] To minimize interference with the pixel pattern of the
display and to avoid viewability of the pattern elements (e.g.,
conductor lines) by the naked eye of a user or viewer, the minimum
dimension of the conductive pattern elements (e.g., the width of a
line or conductive trace) should be less than or equal to
approximately 50 micrometers, or less than or equal to
approximately 25 micrometers, or less than or equal to
approximately 10 micrometers, or less than or equal to
approximately 5 micrometers, or less than or equal to approximately
4 micrometers, or less than or equal to approximately 3
micrometers, or less than or equal to approximately 2 micrometers,
or less than or equal to approximately 1 micrometer, or less than
or equal to approximately 0.5 micrometer.
[0073] In some embodiments, the minimum dimension of conductive
pattern elements is between 0.5 and 50 micrometers, in other
embodiments between 0.5 and 25 micrometers, in other embodiments
between 1 and 10 micrometers, in other embodiments between 1 and 5
micrometers, in other embodiments between 1 and 4 micrometers, in
other embodiments between 1 and 3 micrometers, in other embodiments
between 0.5 and 3 micrometers, and in other embodiments between 0.5
and 2 micrometers. With respect to the reproducible achievement of
useful optical properties (e.g. high transmission and invisibility
of conductive pattern elements with the naked eye) and electrical
properties, and in light of the constraint of using practical
manufacturing methods, preferred values of minimum dimension of
conductive pattern elements are between 0.5 and 5 micrometers, more
preferably between 1 and 4 micrometers, and most preferably between
1 and 3 micrometers.
[0074] In general, the deposited electrically conductive material
reduces the light transmission of the touch sensor, undesirably.
Basically, wherever there is electrically conductive material
deposited, the display is shadowed in terms of its viewability by a
user. The degree of attenuation caused by the conductor material is
proportional to the area fraction of the sensor or region of the
sensor that is covered by conductor, within the conductor
micropattern.
[0075] In general, it is desirable for a transparent touch screen
sensor to exhibit a low value of haze. Haze refers to a property
related to the scattering of light as it passes through a medium,
e.g. as measured by a Haze-Gard instrument (Haze-Gard plus, BYK
Gardner, Columbia, Md.). In some embodiments, the touch screen
sensor exhibits haze less than 10%, in some embodiments less than
5%, in some embodiments less than 4%, in some embodiments less than
3%, in some embodiments less than 2%. Embodiments are disclosed
which achieve a desirable combination of high transmission (also
referred to as visible light transmittance), low haze, and low
conductor trace visibility for regions including conductor
micropatterns. The conductor micropatterns are thus especially
useful when used as part of a sensing area or region of a touch
screen sensor display, e.g. when the micropattern overlays a
viewable region of the display.
[0076] In some embodiments, in order to generate a visible light
transparent display sensor that has uniform light transmission
across the viewable display field, even if there is a non-uniform
distribution of sheet resistance, e.g. derived from a non-uniform
mesh of conductive material, the sensors include isolated conductor
deposits added to the conductor micropattern that serve to maintain
the uniformity of light transmittance across the pattern. Such
isolated conductor deposits are not connected to the drive device
(e.g., electrical circuit or computer) for the sensor and thus do
not serve an electrical function. For example., a metal conductor
micropattern that includes a first region with a mesh of square
grid geometry of 3 micrometer line width and 200 micrometer pitch
(3% of the area is shadowed by the metal, i.e., 97% open area) and
second region with a mesh of square grid geometry of 3 micrometer
line width and 300 micrometer pitch (2% of the area is shadowed by
the metal, i.e., 98% open area) can be made optically uniform in
its average light transmission across the two regions by including
within each of the open cells of the 300 micrometer pitch grid
region one hundred evenly spaced 3 micrometer by 3 micrometer
squares of metal conductor in the pattern. The one hundred 3
micrometer by 3 micrometer squares (900 square micrometers) shadow
an additional 1 percent of the area for each 300 micrometer by 300
micrometer cell (90000 square micrometers), thus making the average
light transmission of the second region equal to that of the first
region. Similar isolated metal features can be added in regions of
space between contiguous transparent conductive regions, e.g.
contiguous transparent conductive regions that include
micropatterned conductors in the form of two dimensional meshes or
networks, in order to maintain uniformity of light transmittance
across the sensor, including the transparent conductive regions and
the region of space between them. In addition to isolated squares
of conductor, other useful isolated deposits of conductor for
tailoring optical uniformity include circles and lines. The minimum
dimension of the electrically isolated deposits (e.g., the edge
length of a square feature, the diameter of a circular feature, or
the width of a linear feature) is less than 10 micrometers, less
than 5 micrometers, less than 2 micrometers, or even less than 1
micrometer.
[0077] With respect to the reproducible achievement of useful
optical properties (e.g. high transmission and invisibility of
conductive pattern elements), using practical manufacturing
methods, the minimum dimension of the electrically isolated
deposits is preferably between 0.5 and 10 micrometers, more
preferably between 0.5 and 5 micrometers, even more preferably
between 0.5 and 4 micrometers, even more preferably between 1 and 4
micrometers, and most preferably between 1 and 3 micrometers. In
some embodiments, the arrangement of electrically isolated
conductor deposits is designed to lack periodicity. A lack of
periodicity is preferred for limiting unfavorable visible
interactions with the periodic pixel pattern of an underlying
display. For an ensemble of electrically isolated conductor
deposits to lack periodicity, there need only be a single
disruption to the otherwise periodic placement of at least a
portion of the deposits, across a region having the deposits and
lacking micropattern elements that are connected to decoding or
signal generation and/or processing electronics. Such electrically
isolated conductor deposits are said to have an aperiodic
arrangement, or are said to be an aperiodic arrangement of
electrically isolated conductor deposits. In some embodiments, the
electrically isolated conductor deposits are designed to lack
straight, parallel edges spaced closer than 10 micrometers apart,
e.g. as would exist for opposing faces of a square deposit with
edge length of 5 micrometers. More preferably the isolated
conductor deposits are designed to lack straight, parallel edges
spaced closer than 5 micrometers apart, more preferably 4
micrometers apart, even more preferably 3 micrometers apart, even
more preferably 2 micrometers apart. Examples of electrically
isolated conductor deposits that lack straight, parallel edges are
ellipses, circles, pentagons, heptagons, and triangles. The absence
within the design of electrically isolated conductor deposits of
straight, parallel edges serves to minimize light-diffractive
artifacts that could disrupt the viewability of a display that
integrates the sensor.
[0078] The impact of the conductor micropattern on optical
uniformity can be quantified. If the total area of the sensor, and
hence the conductor micropattern, that overlays a viewable region
of the display is segmented into an array of 1 millimeter by 1
millimeter regions, preferred sensors include conductor
micropatterns wherein none of the regions have a shadowed area
fraction that differs by greater than 75 percent from the average
for all of the regions. More preferably, none have a shadowed area
fraction that differs by greater than 50 percent. More preferably,
none have a shadowed area fraction that differs by greater than 25
percent. Even more preferably, none have a shadowed area fraction
that differs by greater than 10 percent. If the total area of the
sensor, and hence the conductor micropattern, that overlays a
viewable region of the display is segmented into an array of 5
millimeter by 5 millimeter regions, preferred sensors include
conductor micropatterns wherein none of the regions have a shadowed
area fraction that differs by greater than 50 percent from the
average for all of the regions. Preferably, none have a shadowed
area fraction that differs by greater than 50 percent. More
preferably, none have a shadowed area fraction that differs by
greater than 25 percent. Even more preferably, none have a shadowed
area fraction that differs by greater than 10 percent.
[0079] The disclosure advantageously allows for the use of metals
as the conductive material in a transparent conductive sensor, as
opposed to transparent conducting oxides (TCO's), such as ITO. ITO
has certain drawbacks, such as corrosion-related degradation in
certain constructions, a tendency to crack when flexed, high
attenuation of transmitted light (due to reflection and absorption)
when deposited as a coating with sheet resistance below 100 to 1000
ohms per square, and increasing cost due to the scarcity of indium.
ITO is also difficult to deposit with uniform and reproducible
electrical properties, leading to the need for more complex and
expensive electronics that couple to the conductive pattern to
construct a touch screen sensor.
[0080] Examples of useful metals for forming the electrically
conductive micropattern include gold, silver, palladium, platinum,
aluminum, copper, nickel, tin, alloys, and combinations thereof. In
some embodiments, the conductor is a transparent conducting oxide.
In some embodiments the conductor is ITO. The conductor may have a
thickness between 5 nanometers and 5 micrometers, or between 10
nanometers and 500 nanometers, or between 15 nanometers and 250
nanometers. In many embodiments, the thickness of the conductor is
less than one micrometer. A desired thickness for the conductor can
be calculated by starting with the desired sheet resistance and
considering the micropattern geometry (and in turn its effect on
the current-carrying cross-section in the plane) and the bulk
resistivity of the conductor, as is known in the art. For
complicated geometries of micropattern, there are computational
methods in the art, e.g. finite difference methods or finite
element methods that can be used to calculate sheet resistance,
referred to herein as modeling the properties of a micropattern.
Sheet resistance can be measured using a number of techniques,
including four-point probe techniques and non-contact eddy-current
methods, as are known in the art.
[0081] Examples of useful displays with which sensors of the
invention can be integrated include liquid crystal displays,
cathode ray tube displays, plasma display panels, and organic light
emitting diode displays.
[0082] Conductor patterns according to the invention can be
generated by any appropriate patterning method, e.g. methods that
include photolithography with etching or photolithography with
plating (see, e.g., U.S. Pat. No. 5,126,007; U.S. Pat. No.
5,492,611; U.S. Pat. No. 6,775,907). Additionally, the conductor
patterns can be created utilizing one of several other exemplary
methods (each discussed in more detail below): [0083] 1. Laser
cured masking (curing of a mask layer on a metal film, and then
etching); [0084] 2. Inkjet printing (of masking material or of seed
material for subsequent metal plating); [0085] 3. Gravure printing
(of a seed material for subsequent metal plating); [0086] 4.
Micro-replication (form micro-grooves in a substrate, then fill
with conductive material or with a seed material for subsequent
metal plating); or, [0087] 5. Micro-contact printing (stamping or
rotary printing of self-assembled monolayer (SAM) patterns on a
substrate's surface).
[0088] Utilizing high volume, high resolution printing methods
generally allow for precision placement of the conductive elements,
and also allows for the (pseudo-random) variation of the
microconductors at a scale compatible with commercially available
display pixels, to limit optical anomalies (for example moire
patterns) that might otherwise occur.
[0089] Certain embodiments discussed herein may employ flat-sided
"wire-like" conductors that enable greater light transmission than
existing sensors that utilize transparent conductors. These
flat-sided "wire-like" conductors, in some embodiments, provide
greater scalability and control of conductor placement than is
possible with existing round wire solutions. Micro-conductors
discussed herein include conductors with maximum cross sectional
dimension of 10 micrometers or less. Less than 3 micrometers is
preferred for many sensor applications. Methods of utilizing
masking and etching typically produce a low-aspect (0.05 to 0.5
.mu.m thick.times.1 .mu.m to 10 .mu.m wide) microconductor.
Micro-replicated grooves can produce higher aspect ratio
microconductors, up to greater than 1:1.
[0090] Laser cured masking can be used to create microconductors by
selectively curing a pattern with an ultraviolet laser. Such a
process typically works with either film--(for example, PET) or
glass-based substrates. An exemplary laser cured masking process
may include the following steps: [0091] 1. A substrate is plated
with metal, (for example, silver or copper is sputter coated onto
glass or PET film); [0092] 2. UV curable masking ink is coated
uniformly onto the plated substrate, (for example, spin coating,
and dip coating); [0093] 3. A laser cures a portion of the printed
ink, to form microconductor electrodes in the active area of the
touch sensor, and may also cure (wider) lines that interconnect
electrodes to connector pads (beam width of the laser may be
reduced by a photo mask); [0094] 4. Uncured ink is removed (washed
off); and [0095] 5. Metal plated on the substrate is removed by
etching, except for the pattern under the masking ink.
[0096] Inkjet Printing and plating of seed ink can be used to
create microconductors by printing of the desired pattern using
relatively wide lines of seed ink (catalytic ink), followed by
selective curing with a UV laser, and similar to the laser cured
masking process described above. The substrate for this process may
be either film--(for example, PET) or glass.
[0097] FIG. 3a and FIG. 3b show such a process, whereby: [0098] 1.
Seed ink 66 is inkjet printed onto a substrate 67; [0099] 2. A
laser 65 cures a portion of the printed ink, to form microconductor
electrodes 68 in active area(s) of the touch sensor, and may also
cure (wider) lines that interconnect electrodes to connector pads
(the beam width of the laser may be reduced by a photo mask);
[0100] 3. Uncured ink is removed (washed off); and, [0101] 4. The
cured pattern of seed ink is electroless plated, (with a conductive
metal). The inkjet printing process minimizes the amount of ink
used, so it should be considered where inks are expensive, (for
example, seed inks). If ink has relatively low cost, inkjet
printing can be replaced by another process (for example, spin
coating or dip coating) that coats the whole substrate uniformly.
Ink material and processing for the Inkjet printing and plating of
seed ink process described above are available from Conductive
Inkjet Technology division of Carclo Technical Plastics, Cambridge,
UK.
[0102] Gravure printing requires that the image to be printed is
"etched" into a metal plate which rotates on a drum. As the drum
turns, the etched surface is filled with ink which then gets
deposited on the surface of the film being printed as the
ink-filled etched plate and the film contact each other. The
process is diagramed in FIG. 4, which shows a film substrate 76
being printed with ink lines 74 from ink bath 73. Impression
cylinder 70 is rolls against printing drum 75, which has etches 72
that fill with ink from inkbath 73. Such a process could be used to
make stock material for later processing or could be used to make
specific X or Y components of a high volume sensor.
[0103] Seed inks (or catalytic inks) may be printed by any of the
methods described above. After printing and curing, the inks can be
electroless plated with metals such as copper, resulting in high
conductivity. Seed ink manufacturers include Conductive Inkjet
Technology, a division of Carclo, located in Cambridge, UK and
QinetiQ Company in Farnborough, England. Cabot Printable
Electronics and Displays of Albuquerque, N.M. make inkjet printable
silver conductive inks.
[0104] Micro-replication is yet another process that can be used to
form microcondcutors. The diagram in FIG. 5 shows a cross sectional
view of filled, or partially filled, micro-replicated channels. The
channels may be filled with seed ink 81 and then plated (see
metallization layer 80) to make them conductive. Alternatively the
channels could be filled with an ink that by itself is conductive,
eliminating the need for the plating process. A third alternative
is to coat the substrate with a metal, then mask the portions of
metal in the (bottom of) the grooves, then etch away the unmasked
metal, (see, for example, patent applications No. 61/076731
("Method of Forming a Microstructure") and 61/076736 ("Method of
Forming a Patterned Substrate.")) The actual shape of the channels
can be altered to optimize the cross sectional shape and size that
provides the lowest level of optical interference while still
ensuring high conductivity and high production yields.
[0105] Filled micro-replicated channels can provide a conductor
with a high aspect ratio cross section (relative to masked metal
films). Thus maximum conductivity may be achieved with minimum
optical visibility, (narrow cross section in the direction of
viewing). A method of filling micro-replicated channels and
desirable shapes of channels with high aspect ratio are described
in co-assigned US patent application US2007016081 (Gaides, et.
al.).
[0106] FIG. 6 shows a cross-profile of a high aspect ratio
touch-surface having micro-replicated electrodes that are deeper
than they are wide. In one embodiment, a micro-replicated structure
that has a ratio of depth to width greater than 1:1 will yield
better performance. Generally, the thinner width of the
micro-replicated structure will allow more of the light exiting the
display to pass through the touch sensor. Further, deeper rather
than wider channels will reduce the surface area that will limit
reflection of light entering the sensor from the first surface.
These advantages are gained while not losing capacitive signal.
FIG. 6 shows a finger 85 capacitively coupling with a printed
copper electrodes 87 of touch sensor 86 not only to the top surface
but also to the sides of the sensor.
[0107] Micro-contact printing is yet another process that can be
used to form microcondcutors. Micro-contact printing is the
stamping or rotary printing of self-assembled monolayer (SAM)
patterns on substrate surfaces. The approach exhibits several
technologically important features, including the ability to be
carried out for very fine scale patterns (e.g., feature size of one
tenth of a micrometer) and with the extension of the patterned
monolayer to the patterning of metals, ceramics, and polymers.
[0108] An exemplary micro-contact printing process is as follows:
[0109] 1. A substrate is coated with metal, (for example, silver or
copper is sputter coated or plated onto glass or PET film); [0110]
2. A self-assembled mono-layer mask is stamped onto the plated
substrate; and, [0111] 3. Metal coated on the substrate is removed
by etching, except for the pattern under the mask.
[0112] A micro-contact printing process is described in, for
example, U.S. Pat. No. 5,512,131 (Kumar) and in co-pending 3M
patent application No. 61/032273 ("Methods of Patterning a
Conductor on a Substrate"). Micro-contact printing is generally
substrate independent. For example, substrates can be PET, glass,
PEN, TAC, or opaque plastic. As is known in the art, micro-contact
printing can be combined with metal deposition processes to yield
an additive patterning process (for example, including electroless
plating).
[0113] FIG. 7a shows a matrix sensor for a small capacitive touch
screen. Two patterns (91 and 92) of electrodes, interconnects, and
connector pads are printed on a flexible substrate (for example,
PET). The two patterns are then assembled together to form two
layers of electrodes on parallel planes, with electrodes on the top
plane orthogonal to conductors on the lower plane as shown (see
FIG. 7b). Sometimes, a shield (not shown) is required below the
lower electrode plane.
[0114] The patterns represented in FIG. 7 may be printed using one
of the methods described herein, and a single printing process step
was used to simultaneously print the <10 .mu.m micro-conductors
that form electrodes, and the interconnects lines (typically >10
.mu.m) that carry signals from electrodes to connector pads, and
also the connector pads themselves may be formed in the same print
process. For example, the microcontact printing process was used to
simultaneously print patterns of 3 .mu.m microconductors and 500
.mu.m conductive traces 706 as described with respect to FIG. 27.
This particular embodiment yielded several advantages: [0115] 1.
Alignment of electrodes with interconnects is automatic and very
accurate; [0116] 2. Interconnects can be printed much narrower and
more closely spaced than with othter interconnect printing
processes, (for example, silkscreen printing of conductive inks);
and [0117] 3. The thickness of interconnects (perpendicular to the
plane of the substrate) is much less than with prior interconnect
printing processes, (for example, silkscreen printing of conductive
inks). Thick interconnects cause gaps between laminated layers
which are visible and can undermine the seal between laminated
layers.
[0118] FIG. 8 shows the micro-replicated and filled "stock"
construction material with parallel micro-conductors 95 on a
substrate 96 surface. Web orientation is verticle (97). The
substrate may be PET, PEN, or polycarbonate, and the
micro-conductors may be deposited in micro-replicated grooves as
disclosed herein and/or in 3M patent applications No. 61/076731
("Method of Forming a Microstructure") and 61/076736 ("Method of
Forming a Patterned Substrate"). Spacing of micro-conductors is, in
one embodiment, preferably between 50 .mu.m and 500 .mu.m.
[0119] This stock material may be processed into touch sensor
components (for example, electrodes or shields) by interconnecting
selected micro-conductors with printed (for example, inkjetted, or
silkscreened) dielectrics that provide insulating cross-overs
whereby post-printed (for example, inkjetted or silkscreened)
conductive inks (printed using the methods described herein) can
bridge over some micro-conductors and make contact only with
selected micro-conductors. Thus interconnects and connector pads
are made for a sensor as shown in FIG. 9, which shows an
inkjet-printed dielectric surface 1002 with through-holes 1000
through the dielectric, and conductive traces 1001 also printed by
inkjet. While FIG. 8 and FIG. 9 show micro-conductors printed in
the direction of the substrate web, it is sometimes advantageous to
print micro-conductors in a direction perpendicular to the
substrate web.
[0120] FIG. 10 shows a cross section of an example of a matrix
touch sensor constructed with two layers of the stock
micro-replicated micro-conductor material, and two layers of
post-printed inkjet conductive traces, separated. The topmost layer
1010 includes micro-replicated micro-conductors; the next layer
1011 is a printed dielectric; the next layer 1012 includes
post-processed conductors; the next layer 1013 is an adhesive; the
next layer 1014 is a post-processed conductor; the next layer 1015
is a printed dielectric, and the final layer 1016 includes
micro-replicated microconductors.
[0121] In some embodiments, transparent conductive regions with
different sheet resistance in at least one direction are created by
including selective breaks in conductive traces within an otherwise
continuous and uniform mesh. This approach of selective placement
of breaks is especially useful for generating articles including
patterns of visible transparent conductive regions where the
optical transmittance across the article is uniform. The starting
mesh can be isotropic or anisotropic. For example., an elongated
rectangular transparent conductive bar having a square micromesh
can be made to exhibit periodic sheet resistance along its long
axis by creating a periodic series of breaks, the breaks being in
traces that have a vector component in the direction of the long
axis and the periodicity being in the direction of the long axis.
This periodicity in sheet resistance can be useful for decoding the
position of an object (e.g., a finger) near the rectangular bar. By
selecting the width, thickness, and area density of traces,
together with the population of breaks, one can design periodic
variation in the resistance per unit length along a transparent
conductive element characterized by peaks in resistance per unit
length that are at least 2 times the minimum in resistance per unit
length, preferably at least 5 times their minimum, more preferably
at least 10 times there minimum.
[0122] In other embodiments that include selective breaks in an
otherwise continuous and uniform mesh, the breaks can be placed in
order to create approximately continuously varying sheet resistance
in a given direction. The continuously varying sheet resistance can
be useful for amplifying the non-linearity of electric field along
a transparent conductive element, beyond that which would be
created only by the overall shape of the element. E.g., as is known
in the art, a transparent conductive element with uniform sheet
resistance, in the form of an elongated isosceles triangle with an
electrical potential applied to its base relative to its apex,
exhibits non-linear electric field from base to apex due to the
gradient in resistance per unit length along the field direction
(created by the narrowing width of the triangle). For touch sensors
based on interdigitated arrays of such triangular transparent
conductive elements, it would be advantageous for the non-linearity
in electric field to be even greater, leading to greater
signal-to-noise ratio for circuitry used to decode the position of
an object (e.g., a finger) near the array. By selecting the width,
thickness, and area density of traces, together with the population
of breaks, one can design sheet resistance per unit length along a
transparent conductive element that increases by a factor of at
least 1.1 over a distance of 1 centimeter, or at least 1.2, or at
least 1.5, or at least 2.
[0123] In some embodiments, two transparent conductive regions with
different sheet resistance in at least one direction are created by
including in each of the two regions a contiguous mesh with its own
design, each mesh not necessarily including selectively placed
breaks. Examples of two meshes with designs that lead to different
values of sheet resistance for current passing in a single
direction, e.g. the x direction in FIG. 2, include two meshes with
the same thickness (dimension in the z direction in FIG. 2) of the
same conductive material deposit but with different amounts with
current-carrying cross-sectional area (y-z plane in FIG. 2) per
unit width in the y direction. One example of such a pair of mesh
regions are two square grid regions each comprising conductive
traces of width 2 micrometers but with different pitch, e.g. 100
micrometers and 200 micrometers. Another example of such a pair of
mesh regions are two rectangular grid regions (non-square, with 100
micrometer pitch in the one direction and 200 micrometer pitch in
the orthogonal direction) each comprising conductive traces of
width 2 micrometers but with different orientation, e.g. with the
long axes of the rectangular cells in the first regions oriented at
90 degrees with respect to the rectangular cells in the second
region.
[0124] In some embodiments, the sensors include an insulating
visible light transparent substrate layer that supports a pattern
of conductor, the pattern includes a visible light transparent
micropattern region and a region having a larger feature that is
not transparent, wherein the visible light transparent micropattern
region and the larger feature region include a patterned deposit of
the same conductor (e.g., a metal) at approximately the same
thickness. The larger feature can take the form of, e.g., a wide
conductive trace that makes contact to a visible light transparent
conductive micropattern region or a pad for making contact with an
electronic decoding, signal generation, or signal processing
device. The width of useful larger features, in combination on the
same insulating layer with visible light transparent conductive
micropattern regions, is e.g. between 25 micrometers and 3
millimeters, between 25 micrometers and 1 millimeter, between 25
micrometers and 500 micrometers, between 25 micrometers and 250
micrometers, or between 50 micrometers and 100 micrometers.
[0125] One illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area and a second region micropattern. The
electrically conductive micropattern includes metallic linear
electrically conductive features having a thickness of less than
500 nanometers and a width between 0.5 and 5 micrometers. The first
region micropattern has a first sheet resistance value in a first
direction between 5 and 500 ohm per square, is visible light
transparent, and has between 95% and 99.5% open area. The second
region micropattern has a second sheet resistance value in the
first direction that is different than the first sheet resistance
value.
[0126] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The electrically conductive
micropattern includes metallic linear electrically conductive
features having a thickness of less than 500 nanometers and a width
between 0.5 and 5 micrometers. The first region micropattern has an
anisotropic first sheet resistance with a difference in sheet
resistance values for orthogonal directions of a factor of at least
1.5, is visible light transparent, and has between 95% and 99.5%
open area.
[0127] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area and a second region micropattern. The
electrically conductive micropattern includes metallic linear
electrically conductive features having a thickness of less than
500 nanometers and a width between 1 and 4 micrometers. The first
region micropattern has a first sheet resistance value in a first
direction between 5 and 100 ohm per square, is visible light
transparent, and has between 96% and 99.5% open area. The second
region micropattern has a second sheet resistance value in the
first direction that is different than the first sheet resistance
value.
[0128] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area and a second region micropattern. The
electrically conductive micropattern includes metallic linear
electrically conductive features having a thickness of less than
500 nanometers and a width between 0.5 and 5 micrometers. The first
region micropattern has a first sheet resistance value in a first
direction between 5 and 500 ohm per square, is visible light
transparent, and has between 95% and 99.5% open area. The second
region micropattern has a second sheet resistance value in the
first direction that is different than the first sheet resistance
value. The micropattern also includes electrically isolated
conductor deposits. For all 1 millimeter by 1 millimeter square
regions of the sensor that lie in the visible light transparent
sensing area, none of the regions have a shadowed area fraction
that differs by greater than 75 percent from the average for all of
the regions.
[0129] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area and a second region micropattern. The
electrically conductive micropattern includes metallic linear
electrically conductive features having a thickness of less than
500 nanometers and a width between 0.5 and 5 micrometers. The first
region micropattern has a first sheet resistance value in a first
direction between 5 and 500 ohm per square, is visible light
transparent, and has between 95% and 99.5% open area. The second
region micropattern has a second sheet resistance value in the
first direction that is different than the first sheet resistance
value. The micropattern also includes electrically isolated
conductor deposits. For all 5 millimeter by 5 millimeter square
regions of the sensor that lie in the visible light transparent
sensing area, none of the regions have a shadowed area fraction
that differs by greater than 50 percent from the average for all of
the regions.
[0130] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The electrically conductive
micropattern includes metallic linear electrically conductive
features having a thickness of less than 500 nanometers and a width
between 1 and 4 micrometers. The first region micropattern has an
anisotropic first sheet resistance with a difference in sheet
resistance values for orthogonal directions of a factor of at least
1.5, is visible light transparent, and has between 96% and 99.5%
open area.
[0131] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The electrically conductive
micropattern includes metallic linear electrically conductive
features having a thickness of less than 500 nanometers and a width
between 0.5 and 5 micrometers. The first region micropattern has an
anisotropic first sheet resistance with a difference in sheet
resistance values for orthogonal directions of a factor of at least
1.5, is visible light transparent, and has between 95% and 99.5%
open area. The micropattern also includes electrically isolated
conductor deposits. For all 1 millimeter by 1 millimeter square
regions of the sensor that lie in the visible light transparent
sensing area, none of the regions have a shadowed area fraction
that differs by greater than 75% from the average for all of the
regions.
[0132] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The electrically conductive
micropattern includes metallic linear electrically conductive
features having a thickness of less than 500 nanometers and a width
between 0.5 and 5 micrometers. The first region micropattern has an
anisotropic first sheet resistance with a difference in sheet
resistance values for orthogonal directions of a factor of at least
1.5, is visible light transparent, and has between 95% and 99.5%
open area. The micropattern also includes electrically isolated
conductor deposits. For all 5 millimeter by 5 millimeter square
regions of the sensor that lie in the visible light transparent
sensing area, none of the regions have a shadowed area fraction
that differs by greater than 50 percent from the average for all of
the regions.
[0133] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The first region micropattern includes
metallic linear electrically conductive features having a width
between 0.5 and 5 micrometers. The first region micropattern is
visible light transparent, and has between 95% and 99.5% open area.
For all 1 millimeter by 1 millimeter square regions of the first
region micropattern, none of the square regions have a shadowed
area fraction that differs by greater than 75 percent from the
average for all of the square regions. In one embodiment the first
region micropattern also includes electrically isolated conductor
deposits. In one embodiment, the metallic linear electrically
conductive features have a thickness of less than 500 nanometers.
In one embodiment, the first region micropattern has a first sheet
resistance value in a first direction between 5 and 100 ohm per
meter.
[0134] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The first region micropattern includes
metallic linear electrically conductive features having a width
between 0.5 and 5 micrometers. The first region micropattern is
visible light transparent, and has between 95% and 99.5% open area.
For all 5 millimeter by 5 millimeter square regions of the first
region micropattern, none of the square regions have a shadowed
area fraction that differs by greater than 50 percent from the
average for all of the square regions. In one embodiment, the
metallic linear electrically conductive features have a thickness
of less than 500 nanometers. In one embodiment, the first region
micropattern also includes electrically isolated conductor
deposits.
[0135] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The electrically conductive
micropattern includes metallic linear electrically conductive
features having a thickness of less than 500 nanometers and a width
between 0.5 and 5 micrometers. The first region micropattern has a
first sheet resistance value in a first direction between 5 and 100
ohm per square, is visible light transparent, and has between 95%
and 99.5% open area. The micropattern also includes electrically
isolated conductor deposits. For all 1 millimeter by 1 millimeter
square regions of the sensor that lie in the visible light
transparent sensing area, none of the regions have a shadowed area
fraction that differs by greater than 75 percent from the average
for all of the regions.
[0136] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The electrically conductive
micropattern includes metallic linear electrically conductive
features having a thickness of less than 500 nanometers and a width
between 0.5 and 5 micrometers. The first region micropattern has a
first sheet resistance value in a first direction between 5 and 100
ohm per square, is visible light transparent, and has between 95%
and 99.5% open area. The micropattern also includes electrically
isolated conductor deposits. For all 5 millimeter by 5 millimeter
square regions of the sensor that lie in the visible light
transparent sensing area, none of the regions have a shadowed area
fraction that differs by greater than 50 percent from the average
for all of the regions.
[0137] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area and a second region micropattern. The
electrically conductive micropattern includes metallic linear
electrically conductive features having a thickness of less than
500 nanometers and a width between 0.5 and 5 micrometers. The first
region micropattern has a first sheet resistance value in a first
direction between 5 and 500 ohm per square, is visible light
transparent, and has between 95% and 99.5% open area. The second
region micropattern has a second sheet resistance value in the
first direction that is different than the first sheet resistance
value. The sensor also includes larger electrically conductive
features disposed on or in the visible light transparent substrate,
the larger features comprising a continuous conductor deposit of
the same material and thickness as included in the micropattern and
measuring at least 25 micrometers in minimum dimension.
[0138] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The electrically conductive
micropattern includes metallic linear electrically conductive
features having a thickness of less than 500 nanometers and a width
between 0.5 and 5 micrometers. The first region micropattern has an
anisotropic first sheet resistance with a difference in sheet
resistance values for orthogonal directions of a factor of at least
1.5, is visible light transparent, and has between 95% and 99.5%
open area. The sensor also includes larger electrically conductive
features disposed on or in the visible light transparent substrate,
the larger features comprising a continuous conductor deposit of
the same material and thickness as included in the micropattern and
measuring at least 25 micrometers in minimum dimension.
[0139] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area and a second region micropattern. The
electrically conductive micropattern includes metallic linear
electrically conductive features having a thickness of less than
500 nanometers and a width between 0.5 and 5 micrometers. The first
region micropattern has a first sheet resistance value in a first
direction between 5 and 500 ohm per square, is visible light
transparent, and has between 95% and 99.5% open area. The second
region micropattern has a second sheet resistance value in the
first direction that is different than the first sheet resistance
value. The sensor also includes larger electrically conductive
features disposed on or in the visible light transparent substrate,
the larger features comprising a continuous conductor deposit of
the same material and thickness as included in the micropattern and
measuring at least 500 micrometers in minimum dimension.
[0140] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The electrically conductive
micropattern includes metallic linear electrically conductive
features having a thickness of less than 500 nanometers and a width
between 0.5 and 5 micrometers. The first region micropattern has an
anisotropic first sheet resistance with a difference in sheet
resistance values for orthogonal directions of a factor of at least
1.5, is visible light transparent, and has between 95% and 99.5%
open area. The sensor also includes larger electrically conductive
features disposed on or in the visible light transparent substrate,
the larger features comprising a continuous conductor deposit of
the same material and thickness as included in the micropattern and
measuring at least 500 micrometers in minimum dimension.
[0141] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The first region micropattern includes
conductive traces with width between 0.5 and 10 micrometers. The
first region micropattern is visible light transparent and has
between 90% and 99.95% open area, preferably between 95% and 99.95%
open area, and more preferably between 97% and 98% open area. For
all 5 millimeter by 5 millimeter square regions of the first region
micropattern, none of the square regions have a shadowed area
fraction that differs by greater than 75%, preferably differs by
greater than 50%, more preferably differs by greater than 25%, and
most preferably differs by greater than 10% from the average for
all the square regions. In one embodiment, the first region
micropattern includes conductive traces with width between 0.5 and
5 micrometers, preferably between 1 and 3 micrometers.
[0142] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The first region micropattern includes
conductive traces with width between 1 and 10 micrometers. The
first region micropattern is visible light transparent and has
between 90% and 99.5% open area. The first region micropattern
includes selective breaks in conductive traces within an otherwise
continuous and uniform mesh.
[0143] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The first region micropattern includes
conductive traces with width of about [X+0.5] in units of
micrometers and an open area fraction between [95-X]% and 99.5%.
wherein 0.ltoreq.X.ltoreq.4.5. In one embodiment, the touch screen
sensor within the first region micropattern exhibits a haze value
less than 10% and transmission greater than 75%. In another
embodiment the touch screen sensor within the first region
micropattern exhibits a haze value less than 5% and transmission
greater than 85%. In one embodiment, the first region micropattern
includes conductive traces with width of about [98.5-(2.5X/3.5)]%
and [99.5-(X-3.5)]% wherein 0.ltoreq.X.ltoreq.3.5.
[0144] Another illustrative touch screen sensor includes a visible
light transparent substrate and an electrically conductive
micropattern disposed on or in the visible light transparent
substrate. The micropattern includes a first region micropattern
within a touch sensing area. The first region micropattern includes
parallel conductive traces spaced 4mm apart with width of about 9.6
.mu.m, yielding an open area fraction of 99.75%. This embodiment of
microreplicated electrodes comprises parallel conductors with a
width of about 4 .mu.m, to 10 .mu.m, separated by a distance of 0.5
mm to about 5mm center to center. Conductors may be formed
lengthwise to a web of PET substrate, so lengths of conductors may
be greater than 1 m. Groups of adjacent conductors may be
electrically interconnected to form electrodes of 1 mm to 12 mm
total width, for example, using the process described with respect
to FIG. 8 and FIG. 9. Conductors of adjacent electrodes may be
interconnected such that electrodes are interleaved as disclosed
in, for example, co-pending US Patent Application Publication No.
20070074914.
EXAMPLES
[0145] The following describe exemplary touch screen sensor
designs. They can be fabricated using known photolithographic
methods, e.g. as described in U.S. Pat. No. 5,126,007 or U.S. Pat.
No. 5,492,611. The conductor can be deposited using physical vapor
deposition methods, e.g. sputtering or evaporation, as is known in
the art. Unless otherwise noted, the examples below include
conductors patterned by a micro-contact printing technique (see
technique description above and also co-pending US Patent
Application No. 61/032,273). Each conductive pattern exemplified
herein is useful as a transparent touch screen sensor, when
connected to decoding circuitry, as is known in the art (e.g., U.S.
Pat. No. 4,087,625; U.S. Pat. No. 5,386,219; U.S. Pat. No.
6,297,811; WO 2005/121940 A2).
Example 1
[0146] A micropattern of thin film gold according to the following
description is deposited onto a thin sheet of colorless glass
(approximately 1 millimeter in thickness). The micropattern 240 is
depicted in FIG. 11 and FIG. 12. The thickness or height of the
gold layer is about 100 nanometers. The micropattern 240 involves a
series of horizontal (x-axis) mesh bars 241 comprising horizontal
narrow traces 242, the traces 242 measuring approximately 2
micrometers in width. Four of these horizontal mesh traces 242 are
in electrical communication with a larger feature contact pad 260.
The mesh bars measure approximately 6 millimeters in width.
Accordingly, with thirteen evenly spaced traces 244 traversing a
width (y-axis) of 6 millimeters and thirteen evenly spaced traces
242 traversing a length (x-axis) of 6 millimeters, the pitch of the
square grid of traces is 500 micrometers. As depicted in FIG. 12,
certain traces have breaks 250, measuring approximately 25
micrometers (exaggerated in the figures, for ease in locating). For
a square grid with 2 micrometers wide opaque traces on a 500
micrometer pitch, the fill factor for opaque traces is 0.80%, thus
leading to an open area of 99.20%. For the same square grid, except
with a 25 micrometer break every 500 micrometers, the fill factor
is 0.78%, thus leading to an open area of 99.22%. Thus, the design
includes 1 mm.times.6 mm regions with 99.22% open area and 6
mm.times.6 mm regions with 99.20% open area. The average visible
transmittance of the glass article with mesh is approximately
0.92*0.992=91% (with the factor of 0.92 related to interfacial
reflection losses in light transmission in the
non-conductor-deposited areas of the pattern). Along the horizontal
bar direction, there is a series of complete grid regions connected
together by four traces of gold. Assuming an effective bulk
resistivity of 5E-06 ohm-cm for sputtered thin film gold, each 2
micrometer wide, 500 micrometer long segment of thin film gold has
a resistance of approximately 125 ohms. The regions with a
completed grid, for current passing in the direction of the bars,
have an effective sheet resistance of approximately 115 ohms per
square. The four traces connecting the regions with completed grids
create approximately 62.5 ohms of resistance between the regions.
The above described arrangement of conductive trace elements leads
to a spatially varying resistance per unit length along the bar
direction as plotted in FIG. 13. FIG. 14 illustrates an equivalent
circuit for the array of horizontal mesh bars. The circuit has a
series of plates connected by resistors.
Example 2
[0147] A micropattern of thin film gold according to the following
description is deposited onto a thin sheet of colorless glass
(approximately 1 millimeter in thickness). The micropattern 340 is
depicted in FIG. 15. The thickness of the gold is about 100
nanometers. The micropattern 340 has transparent conductive regions
in the form of a series of interdigitated wedges or triangles. Each
wedge is comprised of a mesh made up of narrow metallic traces 342,
344, the traces 342, 344 (see FIG. 15a-FIG. 15c) measuring
approximately 2 micrometers in width. The mesh wedges measure
approximately 1 centimeter in width at their base and approximately
six centimeters in length. The pitch of the square grid of traces
342, 344 is 500 micrometers. Within selected regions of the mesh
(see FIG. 15a-FIG. 15b), within a wedge, breaks 350 measuring
approximately 25 micrometers in length are placed intentionally to
affect the local sheet resistance within the wedge, for current
passing along its long axis. As depicted in FIG. 15a and FIG. 15b,
regions 15a and 15b (the regions being separated by approximately 1
centimeter in FIG. 15), breaks 350 are included in the mesh that
increase the sheet resistance in the direction of the long axis by
a factor greater than 1.2. The overall design also includes region
15c (as depicted in FIG. 15c), which is electrically isolated and
spaced apart from regions 15a and 15b, and which has a mesh of with
sheet resistance value less than those of regions 15a and 15b. The
mesh region 15c has an open area of 99.20%, while the mesh regions
15a and 15b have open area fractions of 99.20% and 99.21%
respectively. The overall design also includes regions 15d and 15e
(as depicted in FIG. 15d and FIG. 15e) with meshes of larger pitch
than regions 15a, 15b and 15c, but with the same width of traces,
leading to increased sheet resistance and visible
transmittance.
[0148] FIG. 16 illustrates the effect of engineering the mesh
properties as described above on the gradient in resistance along a
wedge, versus the use of a standard ITO coating for the same shape
of region. The overall design also includes larger conductive
features in the form of conductive leads along the left and right
sides of the pattern, the leads being approximately 1 millimeter
wide and patterned from thin film gold with approximately 100
nanometers thickness.
Example 3
[0149] A transparent sensor element 400 for a touch screen sensor
is illustrated in FIG. 17. The sensor element 400 includes two
patterned conductor layers 410, 414, (e.g., an X axis layer and a Y
axis layer) two optically clear adhesive layers 412, 416, and a
base plate 418, laminated together and depicted as separated in
FIG. 17 for clarity. Layers 410 and 414 include transparent
conductive mesh bars where one layer is oriented in the x axis
direction and the other layer is orientated in the y axis
direction, with reference to FIG. 2. The base plate 418 is a sheet
of glass measuring 6 centimeter by 6 centimeters in area and 1
millimeter in thickness. A suitable optically clear adhesive is
Optically Clear Laminating Adhesive 8141 from 3M Company, St. Paul,
Minn. For each of the X-layer and the Y-layer, a clear polymer film
with a micropattern of metal is used. A micropattern of thin film
gold according to the following description is deposited onto a
thin sheet of PET. Suitable PET substrates include ST504 PET from
DuPont, Wilmington, Del., measuring approximately 125 micrometers
in thickness.
[0150] The micropattern 440 is depicted in FIG. 18 and FIG. 19. The
thickness of the gold is about 100 nanometers. The micropattern has
transparent conductive regions in the form of a series of parallel
mesh bars 442. In addition to mesh bars that are terminated with
square pads 460 (approximately 2 millimeters by 2 millimeters in
area, comprising continuous conductor in the form of thin film gold
with thickness approximately 100 nanometers) for connection to an
electronic device for capacitive detection of finger touch to the
base plate, there are mesh bars 441 that are electrically isolated
from the electronic device. The isolated mesh bars 441 serve to
maintain optical uniformity across the sensor. Each bar is
comprised of a mesh made up of narrow metallic traces 443, the
traces 443 measuring approximately 5 micrometers in width. The mesh
bars each measure approximately 2 millimeters in width and 66
millimeters in length. Within each mesh bar are rectangular cells
measuring approximately 0.667 millimeters in width and 12
millimeters in length. This mesh design serves to provide ties
between long-axis traces in each mesh bar, to maintain electrical
continuity along the mesh bar, in case of any open-circuit defects
in the long axis traces. However, as opposed to the use of a square
mesh with 0.667 millimeter pitch having such ties, the rectangular
mesh of FIG. 18 and FIG. 19 trades off sheet resistance along the
mesh bar with optical transmittance more optimally. More
specifically, the mesh bar depicted in FIG. 18 and FIG. 19 and a 2
millimeter wide mesh bar comprising a square mesh with 0.667
millimeter pitch would both have essentially the same sheet
resistance along the long axis of the mesh bar (approximately 50
ohms per square); however, the square grid would occlude 1.5% of
the area of the transparent conductive region and the mesh depicted
in FIG. 18 and FIG. 19 occludes only 0.8% of the area of the
transparent conductive region.
Example 4
[0151] A transparent sensor element for a touch screen sensor is
described. The sensor element includes two patterned conductor
layers, two optically clear adhesive layers, and a base plate as
depicted in FIG. 17. The base plate is a sheet of glass measuring 6
centimeter by 6 centimeters in area and 1 millimeter in thickness,
laminated together as depicted in FIG. 17. A suitable optically
clear adhesive is Optically Clear Laminating Adhesive 8141 from 3M
Company. For each of the X-layer and the Y-layer, a clear polymer
film with a micropattern of metal is used. A micropattern of thin
film gold according to the following description is deposited onto
a thin sheet of PET. Suitable PET substrates include ST504 PET from
DuPont, measuring approximately 125 micrometers in thickness.
[0152] The micropattern 540 is depicted in FIG. 20 and FIG. 21. The
thickness of the gold is 100 nanometers. The micropattern 540 has
transparent conductive regions in the form of a series of parallel
mesh bars 542. In addition to mesh bars 542 that are terminated
with square pads 560 for connection to an electronic device for
capacitive detection of finger touch to the base plate, there are
straight line segments 541 that are electrically isolated from the
electronic device. The straight line segments 541 lie in regions
between the mesh bars 542, with essentially the same geometry as
the mesh bars, except for approximately 25 micrometer breaks 550 as
depicted in FIG. 13. The isolated line segments 541 serve to
maintain optical uniformity across the sensor. Each bar 542 is
comprised of a mesh made up of narrow metallic traces, the traces
measuring approximately 5 micrometers in width. The mesh bars 542
each measure approximately 2 millimeters in width and 66
millimeters in length. Within each mesh bar 542 are rectangular
cells measuring approximately 0.667 millimeters in width and 12
millimeters in length. The mesh 542 depicted in FIG. 12 and FIG. 13
occludes 0.8% of its area within the transparent conductive region.
The isolated line segments 541 depicted in FIG. 12 and FIG. 13 also
occlude 0.8% of the area within the region they occupy between the
mesh bars 542.
Example 5
[0153] A transparent sensor element for a touch screen sensor is
described. The sensor element includes two patterned conductor
layers, two optically clear adhesive layers, and a base plate as
depicted in FIG. 17. The base plate is a sheet of glass measuring 6
centimeter by 6 centimeters in area and 1 millimeter in thickness,
laminated together as depicted in FIG. 17. A suitable optically
clear adhesive is Optically Clear Laminating Adhesive 8141 from 3M
Company. For each of the X-layer and the Y-layer, a clear polymer
film with a micropattern of metal is used. A micropattern of thin
film gold according to the following description is deposited onto
a thin sheet of PET. Suitable PET substrates include ST504 PET from
DuPont, measuring approximately 125 micrometers in thickness.
[0154] The micropattern 640 is depicted in FIG. 22 and FIG. 23. The
thickness of the gold is about 100 nanometers. The micropattern 640
has transparent conductive regions in the form of a series of
parallel mesh bars 642. In addition to mesh bars 642 that are
terminated with square pads 660 for connection to an electronic
device for capacitive detection of finger touch to the base plate,
there are straight line segments 641 that are electrically isolated
from the electronic device. The straight line segments 641 lie in
regions between the mesh bars, with a similar geometry to the line
segments of the mesh bars. The electrically isolated line segments
641 serve to maintain optical uniformity across the sensor. Each
bar 641, 642 is comprised of narrow metallic traces, the traces
measuring approximately 3 micrometers in width. The mesh bars 642
each measure approximately 2 millimeters in width and 66
millimeters in length. Within each mesh bar 642 comprising randomly
shaped cells. The mesh 642 depicted in FIG. 22 and FIG. 23 occludes
less than 5 percent of its area within the transparent conductive
region. The isolated line segments 641 depicted in FIG. 22 and FIG.
23 also occlude less than 5 percent of the area within the region
they occupy between the mesh bars.
Preparation of Metalized Polymer Film Substrates e.g.s 6 Through
40
[0155] A polymer film substrate was provided,
polyethyleneterephthalate (PET) (ST504, E. I. DuPont de Nemours and
Company, Wilmington, Del.). The optical properties of the ST504 PET
film were determined by Haze-Gard. The haze and the transmission
measured approximately 0.67% and 92.9%, respectively.
[0156] Some substrate films were coated with gold and some were
coated with silver. The gold-coated substrates were prepared by
thermal evaporation (DV-502A, Denton Vacuum, Moorestown, N.J.). For
gold-coated substrates, the substrate surface was first coated with
20 angstroms of chromium and then coated with 100 nanometers of
gold. In the case of silver-coated substrates, two different
methods were used. Some silver-coated substrates were prepared by
both thermal evaporation (DV-502A, Denton Vacuum, Moorestown, N.J.)
and some were prepared by sputtering (3M). The substrate surface
was coated with 100 nanometers of silver in all cases.
Stamp Fabrication
[0157] Two different master tools for molding elastomeric stamps
were generated by preparing patterns of photoresist (Shipley1818,
Rohm and Haas Company, Philadelphia, Pa.) on 10-centimeter diameter
silicon wafers using photolithography. The different master tools
were based on two different mesh shapes, herein referred to as
"Hex" and "Square". Hex refers to a pattern comprising a network of
lines that define enclosed areas having the shape of a regular
hexagon. Square refers to a pattern comprising a network of lines
that define enclosed areas having the shape of squares. An
elastomeric stamp was molded against the master tool by pouring
uncured polydimethylsiloxane (PDMS, Sylgard.TM. 184, Dow Corning,
Midland Mich.) over the tool to a thickness of approximately 3.0
millimeters. The uncured silicone in contact with the master was
degassed by exposing to a vacuum, and then cured for 2 hours at
70.degree. C. After peeling from the master tool, a PDMS stamp was
provided with a relief pattern comprising raised features
approximately 1.8 micrometers in height. For both hex mesh and
square mesh stamps, the raised features of were the lines defining
the respective mesh geometry, as described above.
Inking
[0158] The stamp was inked by contacting its back side (flat
surface without relief pattern) to a solution of octadecylthiol
("ODT" O0005, TCI AMERICA, Wellesley Hills, Mass.) in ethanol for
20 hours. 10 mM of ODT solution was used for the stamp with square
mesh pattern, and 5 mM of ODT solution was used for the stamp with
hex mesh pattern.
Stamping
[0159] Metalized polymer film substrates were stamped with inked
stamps as described above. For stamping, the metalized film was
contacted to the stamp relief patterned-surface, which was face up,
by first contacting an edge of the film sample to the stamp surface
and then rolling the film into contact across the stamp, using a
foam roller with diameter of approximately 3.0 centimeters. The
rolling step required less than 1 second to execute. After rolling
step, the substrate was contacted with the stamp for 10 seconds.
Then, the substrate was peeled from the stamp, a step that required
less than 1 second.
Etching
[0160] After stamping, the metallized film substrate with printed
pattern was immersed into an etchant solution for selective etching
and metal patterning. For printed metalized film substrates bearing
a gold thin film, the etchant comprised 1 gram of thiourea (T8656,
Sigma-Aldrich, St. Louis, Mo.), 0.54 milliliter of concentrated
hydrochloric acid (HX0603-75, EMD Chemicals, Gibbstown, N.J.), 0.5
milliliter of hydrogen peroxide (30%, 5240-05, Mallinckrodt Baker,
Phillipsburg, N.J.), and 21 grams of deionized water. To pattern
the gold thin film, the printed metalized film substrate was
immersed in the etch solution for 50 seconds. For printed metalized
film substrates bearing a silver thin film, the etchant comprised
0.45 grams of thiourea (T8656, Sigma-Aldrich, St. Louis, Mo.), 1.64
grams of ferric nitrate (216828, Sigma-Aldrich, St. Louis, Mo.),
and 200 milliliter of deionized water. To pattern the silver thin
film, the printed metalized film substrate was immersed in the etch
solution for 3 minutes. After patterned etching of the gold,
residual chromium was etched using a solution of 2.5 grams of
potassium permanganate (PX1551-1, EMD Chemicals, Gibbstown, N.J.),
4 grams of potassium hydroxide (484016, Sigma-Aldrich, St. Louis,
Mo.), and 100 milliliters of deionized water.
Characterization
[0161] After selective etching and metal patterning, the metal
patterns were characterized using an optical microscope (Model
ECLIPSE LV100D equipped with a DS-Fi1 digital camera and
NIS-Elements D software, Nikon, Melville, N.Y.), scanning electron
microscope (SEM, Model JSM-6400, JEOL Ltd, Tokyo, Japan), and
Haze-Gard (Haze-Gard plus, BYK Gardner, Columbia, Md.). The
microscopic techniques were used to determine the width of line
features in the metal pattern. Haze-Gard was used to determine the
transmission and the haze for the mesh-grid coated films. The
HazeGard measurements were done after laminating the patterned film
on a glass with an optical clear adhesive (3M Product). The
visibility factor of high, medium, and low was assigned to describe
the degree of visibility of line features in the metal pattern
(human observation with unaided eye).
Example 6
[0162] A hexagonal mesh grid pattern of thin film gold was
fabricated and characterized according to the procedures described
above. The ink solution comprised octadecylthiol dissolved in
ethanol at a concentration of 5 mM. The ink solution was contacted
to the back side of the stamp for 20 hours. The stamping time was
10 seconds. FIG. 1 gives an SEM photomicrograph recorded from the
completed thin film gold micropattern. The actual line width
measured approximately 1.63 micrometers. The percentage of open
area was recalculated based on the measured line width and the
designed edge-to-edge width of 400 micrometers, which is 99.2%. The
optical properties of the gold Hex mesh grid coated film were
determined by Haze-Gard. The haze and the transmission measured
approximately 1.14% and 91.6%, respectively. High visibility was
assigned to this example because the gold Hex mesh pattern with a
line width of 1.63 micrometers and an edge-to-edge width of 400
micrometers can be easily seen.
Examples 7 to 15
[0163] Hexagonal mesh grid patterns of thin film gold were
fabricated and characterized according to the procedures described
in Example 1. The actual line width for each example was measured
using SEM and listed in Table 1. The percentage of open area was
then recalculated based on the actual line width and designed
edge-to-edge width and listed in Table 1. Table 1 also gives the
haze value and the transmission value for each example measured by
Haze-Gard and the visibility factors assigned to each example.
Example 16
[0164] A square mesh grid pattern of thin film gold was fabricated
and characterized according to the procedures described above. The
ink solution comprised octadecylthiol dissolved in ethanol at a
concentration of 10 mM. The ink solution was contacted to the back
side of the stamp for 20 hours. The stamping time was 10 seconds.
The actual line width measured approximately 4.73 micrometers using
optical microscope. The percentage of open area was recalculated
based on the measured line width and the designed pitch of 320
micrometers, which is 97.0%. The optical properties of the gold
Square mesh grid coated film were determined by Haze-Gard. The haze
and the transmission measured approximately 1.58% and 88.6%,
respectively. High visibility was assigned to this example because
the gold Square mesh pattern with a line width of 4.73 micrometers
and a pitch of 320 micrometers can be easily seen.
Examples 17-23
[0165] Square mesh grid patterns of thin film gold were fabricated
and characterized according to the procedures described in Example
11. The actual line width for each example was measured using
optical microscope and listed in Table 1. The percentage of open
area was then recalculated based on the actual line width and
designed pitch and listed in Table 1. Table 1 also gives the haze
value and the transmission value for each example measured by
Haze-Gard and the visibility factors assigned to each example.
Example 24
[0166] A hex mesh grid pattern of thin film silver was fabricated
and characterized according to the procedures described above. The
silver-coated substrates were prepared by sputtering. The ink
solution comprised octadecylthiol dissolved in ethanol at a
concentration of 5 mM. The ink solution was contacted to the back
side of the stamp for 20 hours. The stamping time was 10 seconds.
FIG. 2 gives an SEM photomicrograph recorded from the completed
thin film silver micropattern. The actual line width measured
approximately 2.43 micrometers. The percentage of open area was
recalculated based on the measured line width and the designed
edge-to-edge width of 600 micrometers, which is 99.2%. The optical
properties of the gold Hex mesh grid coated film were determined by
Haze-Gard. The haze and the transmission measured approximately
1.19% and 91.8%, respectively. High visibility was assigned to this
example because the silver Hex mesh pattern with a line width of
2.43 micrometers and an edge-to-edge width of 600 micrometers can
be easily seen.
Examples 25 to 32
[0167] Hex mesh grid patterns of thin film silver were fabricated
and characterized according to the procedures described in Example
19. The actual line width for each example was measured using SEM
and listed in Table 1. The percentage of open area was then
recalculated based on the actual line width and designed
edge-to-edge width and listed in Table 1. Table 1 also gives the
haze value and the transmission value for each example measured by
Haze-Gard and the visibility factors assigned to each example.
Example 33
[0168] A Square mesh grid pattern of thin film silver was
fabricated and characterized according to the procedures described
above. The silver-coated substrates were prepared by thermal
evaporation. The ink solution comprised octadecylthiol dissolved in
ethanol at a concentration of 10 mM. The ink solution was contacted
to the back side of the stamp for 20 hours. The stamping time was
10 seconds. The actual line width measured approximately 5.9
micrometers using optical microscope. The percentage of open area
was recalculated based on the measured line width and the designed
pitch of 320 micrometers, which is 96.3%. The optical properties of
the silver Square mesh grid coated film were determined by
Haze-Gard. The haze and the transmission measured approximately
1.77% and 88.9%, respectively. High visibility was assigned to this
example because the silver Square mesh pattern with a line width of
5.9 micrometers and a pitch of 320 micrometers can be easily
seen.
Examples 34-40
[0169] Square mesh grid patterns of thin film silver were
fabricated and characterized according to the procedures described
in Example 28. The actual line width for each example was measured
using optical microscope and listed in Table 1. The percentage of
open area was then recalculated based on the actual line width and
designed pitch and listed in Table 1. Table 1 also gives the haze
value and the transmission value for each example measured by
Haze-Gard and the visibility factors assigned to each example.
TABLE-US-00001 TABLE 1 Open Line area Example Metal Mesh width
fraction Haze Transmission Visibility number type geometry (.mu.m)
(%) (%) (%) of Lines Region.sup.1 6 Gold Hex 1.63 99.2 1.14 91.6
High 2 7 Gold Hex 2.92 99.0 1.04 91.6 High 2 8 Gold Hex 2.91 99.0
1.2 91.5 High 2 9 Gold Hex 1.92 98.7 1.37 91.4 Medium 1 10 Gold Hex
2.14 97.9 1.61 91.2 Low 1 11 Gold Hex 1.84 98.2 1.62 90.9 Low 1 12
Gold Hex 2.65 98.2 1.42 90.8 Medium 1 13 Gold Hex 2.69 97.3 1.76
90.6 Low 1 14 Gold Hex 1.13 97.7 2.57 90.3 Low 2 15 Gold Hex 2.27
97.7 1.78 90.3 Low 1 16 Gold Square 4.73 97.0 1.58 88.6 High 2 17
Gold Square 3.01 96.2 2.33 88.4 Medium 2 18 Gold Square 4.7 94.1
1.95 86.0 Medium 2 19 Gold Square 3.01 92.5 3.77 85.6 Low 2 20 Gold
Square 4.49 91.4 2.77 83.3 Low 2 21 Gold Square 3.18 87.3 5.45 81.1
Low 3 22 Gold Square 4.73 88.2 3.11 80.9 Low 3 23 Gold Square 2.82
86.9 6.68 79.1 Low 3 24 Silver Hex 2.43 99.2 1.19 91.8 High 2 25
Silver Hex 2.18 99.3 1.45 91.7 High 2 26 Silver Hex 1.92 99.0 1.39
91.5 High 2 27 Silver Hex 2.44 98.4 1.62 91.3 Medium 1 28 Silver
Hex 0.94 99.1 1.92 91.2 Low 1 29 Silver Hex 2.18 98.6 1.92 91.0
Medium 1 30 Silver Hex 2.55 97.5 1.93 90.8 Low 1 31 Silver Hex 1.81
98.2 1.96 90.7 Low 1 32 Silver Hex 2.89 97.1 2.04 90.0 Low 1 33
Silver Square 5.9 96.3 1.77 88.9 High 3 34 Silver Square 3.35 95.8
2.46 88.0 Medium 2 35 Silver Square 5.57 93.1 2.55 86.2 Medium 3 36
Silver Square 2.76 93.1 3.99 85.0 Low 2 37 Silver Square 5.74 89.1
3.49 83.6 Low 3 38 Silver Square 5.7 85.8 4.09 80.8 Low 3 39 Silver
Square 2.98 88.1 5.69 80.2 Low 3 40 Silver Square 2.78 87.1 7.0
77.6 Low 3 .sup.1Region refers to the different regions as shown
and labeled in FIG. 24.
Example 41
[0170] A transparent sensor element was fabricated and combined
with a touch sensor drive device as generally shown in FIGS. 27, 28
and 29. The device was then integrated with a computer processing
unit connected to a display to test the device. The device was able
to detect the positions of multiple single and or simultaneous
finger touches, which was evidenced graphically on the display.
This example used micro-contact printing and etching techniques
(see also co-pending US Patent App. No. 61/032,273) to form the
micro-conductor pattern used in the touch sensor.
Formation of a Transparent Sensor Element
[0171] First Patterned Substrate
[0172] A first visible light substrate made of polyethylene
terephthalate (PET) having a thickness of 125 micrometers (.mu.m)
was vapor coated with 100 nm silver thin film using a thermal
evaporative coater to yield a first silver metalized film. The PET
was commercially available as product number ST504 from E.I. du
Pont de Nemours, Wilmington, Del. The silver was commercially
available from Cerac Inc., Milwaukee, Wis. as 99.99% pure 3 mm
shot.
[0173] A first poly(dimethylsiloxane) stamp, referred to as PDMS
and commercially available as product number Sylgard 184, Dow
Chemical Co., Midland, Mich., having a thickness of 3 mm, was
molded against a 10 cm diameter silicon wafer (sometimes referred
to in the industry as a "master") that had previously been
patterned using standard photolithography techniques. The PDMS was
cured on the silicon wafer at 65.degree. C. for 2 hours.
Thereafter, the PDMS was peeled away from the wafer to yield a
first stamp having two different low-density regions with patterns
of raised features, a first continuous hexagonal mesh pattern and a
second discontinuous hexagonal mesh pattern. That is, the raised
features define the edges of edge-sharing hexagons. A discontinuous
hexagon is one that contains selective breaks in a line segment.
The selective breaks had a length less than 10 .mu.m. The breaks
were designed and estimated to be approximately 5 .mu.m. In order
to reduce their visibility, it found that, preferably, the breaks
should be less than 10 .mu.m, more preferably, 5 .mu.m or less,
e.g., between 1 and 5 .mu.m. Each raised hexagon outline pattern
had a height of 2 .mu.m, had 1% to 3% area coverage, corresponding
to 97% to 99% open area, and line segments that measured from 2 to
3 .mu.m in width. The first stamp also included raised features
defining 500 .mu.m wide traces. The first stamp has a first
structured side that has the hexagonal mesh pattern regions and the
traces and an opposing second substantially flat side.
[0174] The stamp was placed, structured side up, in a glass Petri
dish containing 2mm diameter glass beads. Thus, the second,
substantially flat side was in direct contact with the glass beads.
The beads served to lift the stamp away from the base of the dish,
allowing the following ink solution to contact essentially all of
the flat side of the stamp. A 10 millimolar ink solution of
1-octadecanethiol (product number C18H3CS, 97%, commercially
available from TCI America, Portland Oreg.) in ethanol was pipetted
into the Petri dish beneath the stamp. The ink solution was in
direct contact with the second substantially flat side of the
stamp. After sufficient inking time (e.g., 3 hours) where the ink
has diffused into the stamp, the first stamp was removed from the
petri dish. The inked stamp was placed, structured side up, onto a
working surface. The first silver metalized film was applied using
a hand-held roller onto the now inked structured surface of the
stamp such that the silver film was in direct contact with the
structured surface. The metalized film remained on the inked stamp
for 15 seconds. Then the first metalized film was removed from the
inked stamp. The removed film was placed for three minutes into a
silver etchant solution, which contained (i) 0.030 molar thiourea
(product number T8656, Sigma-Aldrich, St. Louis, Mo.) and (ii)
0.020 molar ferric nitrate (product number 216828, Sigma-Aldrich)
in deionized water. After the etching step, the resulting first
substrate was rinsed with deionized water and dried with nitrogen
gas to yield a first patterned surface. Where the inked stamp made
contact with the silver of the first metalized substrate, the
silver remained after etching. Thus silver was removed from the
locations where contact was not made between the inked stamp and
silver film.
[0175] FIGS. 27, 27a and 27b show a first patterned substrate 700
having a plurality of first continuous regions 702 alternating
between a plurality of first discontinuous regions 704 on a first
side of the substrate, which is the side that contained the now
etched and patterned silver metalized film. The substrate has an
opposing second side that is substantially bare PET film. Each of
the first regions 702 has a corresponding 500 .mu.m wide conductive
trace 706 disposed at one end. FIG. 27a shows an exploded view of
the first region 702 having a plurality of continuous lines forming
a hexagonal mesh structure. FIG. 27b shows an exploded view of the
first discontinuous region 704 having a plurality of discontinuous
lines (shown as selective breaks in each hexagon) forming a
discontinuous hexagonal mesh structure. Each mesh structure of
regions 702 and 704 had 97% to 99% open area. Each line segment
measured from 2 to 3 .mu.m.
[0176] Second Patterned Substrate
[0177] The second patterned substrate was made as the first
patterned substrate using a second visible light substrate to
produce a second silver metalized film. A second stamp was produced
having a second continuous hexagonal mesh pattern interposed
between a second discontinuous hexagonal mesh pattern.
[0178] FIGS. 28, 28a and 28b show a second patterned substrate 720
having a plurality of second continuous regions 722 alternating
between a plurality of second discontinuous regions 724 on a first
side of the second substrate. Each of the second regions 722 has a
corresponding 500 .mu.m wide second conductive trace 726 disposed
at one end. FIG. 28a shows an exploded view of one second region
722 having a plurality of continuous lines forming a hexagonal mesh
structure. FIG. 28b shows an exploded view of one second
discontinuous region 724 having a plurality of discontinuous lines
(shown as selective breaks in each hexagon) forming discontinuous
hexagonal mesh structure. The selective breaks had a length less
than 10 .mu.m. The breaks were designed and estimated to be
approximately 5 .mu.m. In order to reduce their visibility, it
found that, preferably, the breaks should be less than 10 .mu.m,
more preferably, 5 .mu.m or less, e.g., between 1 and 5 .mu.m. Each
mesh structure of region 722 and 724 had 97% to 99% open area. Each
line segment measured from 2 to 3 .mu.m.
Formation of a Projected Capactive Touch Screen Sensor Element
[0179] The first and second patterned substrates made above were
used to produce a two-layer projected capacitive touch screen
transparent sensor element as follows.
[0180] The first and second patterned substrates were adhered
together using Optically Clear Laminating Adhesive 8141 from 3M
Company, St. Paul, Minn. to yield a multilayer construction. A
handheld roller was used to laminate the two patterned substrates
with the regions of the first and second conductive trace regions
706 and 726 being adhesive free. The multilayer construction was
laminated to a 0.7 mm thick float glass using Optically Clear
Laminating Adhesive 8141 such that the first side of the first
substrate was proximate to the float glass. The adhesive free first
and second conductive trace regions 706 and 726 allowed electrical
connection to be made to the first and second patterned substrates
700 and 720.
[0181] FIG. 29 shows a top plan view of a multilayer touch screen
sensor element 740 where the first and second patterned substrate
have been laminated. Region 730 represented the overlap of the
first and second continuous regions. Region 732 represented the
overlap of the first continuous region and the second discontinuous
region. Region 734 represented the overlap of the second continuous
region and the first discontinuous region. And, region 736
represented the overlap between the first and second discontinuous
regions. While there was a plurality of these overlap regions, for
ease of illustration, only one region of each has been depicted in
the figure.
[0182] The integrated circuits used to make mutual capacitance
measurements of the transparent sensor element were PIC18F87J10
(Microchip Technology, Chandler, Ariz.), AD7142 (Analog Devices,
Norwood, Mass.), and MM74HC154WM (Fairchild Semiconductor, South
Portland, Me.). The PIC18F87J10 was the microcontroller for the
system. It controlled the selection of sensor bars which
MM74HC154WM drives. It also configured the AD7142 to make the
appropriate measurements. Use of the system included setting a
number of calibration values, as is known in the art. These
calibration values can vary from touch screen to touch screen. The
system could drive 16 different bars and the AD7142 can measure 12
different bars. The configuration of the AD7142 included selection
of the number of channels to convert, how accurately or quickly to
take measurements, if an offset in capacitance should be applied,
and the connections for the analog to digital converter. The
measurement from the AD7142 was a 16 bit value representing the
capacitance of the cross point between conductive bars in the
matrix of the transparent sensor element.
[0183] After the AD7142 completed its measurements it signaled the
microcontroller, via an interrupt, to tell it to collect the data.
The microcontroller then collected the data over the SPI port.
After the data was received, the microcontroller incremented the
MM74HC154WM to the next drive line and cleared the interrupt in the
AD7142 signaling it to take the next set of data. While the
sampling from above was constantly running, the microcontroller was
also sending the data to a computer with monitor via a serial
interface. This serial interface allowed a simple computer program,
as are known to those of skill in the art, to render the raw data
from the AD7142 and see how the values were changing between a
touch and no touch. The computer program rendered different color
across the display, depending on the value of the 16 bit value.
When the 16 bit value was below a certain value, based on the
calibration, the display region was rendered white. Above that
threshold, based on the calibration, the display region was
rendered green. The data were sent asynchronously in the format of
a 4 byte header (0xAAAAAAAA), one byte channel (0x00-0x0F), 24
bytes of data (represents the capacitive measurements), and
carriage return (0x0D).
Results of Testing of the System
[0184] The transparent sensor element was connected to the touch
sensor drive device. When a finger touch was made to the glass
surface, the computer monitor rendered the position of touch that
was occurring within the touch sensing region in the form of a
color change (white to green) in the corresponding location of the
monitor. When two finger touches were made simultaneously to the
glass surface, the computer monitor rendered the positions of
touches that were occurring within the touch sensing region in the
form of a color change (white to green) in the corresponding
locations of the monitor. When three finger touches were made
simultaneously to the glass surface, the computer monitor rendered
the positions of touches that were occurring within the touch
sensing region in the form of a color change (white to green) in
the corresponding locations of the monitor.
Example 42
[0185] One embodiment of microreplicated electrodes comprises
parallel conductors with a width of about 0.5 to about 5 microns (Y
dimension in FIG. 5), separated by a distance of about 2 mm to
about 5 mm center to center. Groups of adjacent conductors may be
electrically interconnected to form electrodes of 1 mm to 10 mm
total width, for example, using the process described with respect
to FIG. 8 and FIG. 9.
[0186] The traces were made by forming rectangular microreplicated
grooves 10 .mu.m wide (X dimension in FIG. 5), 20 .mu.m deep (Z
dimension in FIG. 5), spaced 4 mm apart on a transparent substrate
of PET using methods described herein and by reference. The
parallel array of grooves was 100 mm wide. Grooves were printed in
the PET web direction so their length was the length of the web,
(>20 meters).
[0187] Grooves were filled with a seed ink manufactured by
Conductive Inkjet Technologies, (CIT). A thin layer of ink was
smoothed over the grooves then excess was removed with a doctor
blade in a process similar to silk screening. The seed ink was then
cured using UV light. The substrate with ink-filled grooves was
then electroless plated with copper. The resulting microconductors
were each approximately 9.6 .mu.m wide. The ink filling, UV curing,
and electroless plating process was performed by CIT.
Microconductors with substrates with grooves <10 .mu.m wide, 20
.mu.m deep, spaced 2 mm were also made using the process
described.
Visually Obscuring the Conductive Micropattern Elements
[0188] In some of the embodiments herein described, it is desirable
to take additional measures to reduce the visibility of the
conductive micropattern elements. Despite their small size, when
patterned in certain ways, and when exposed sometimes to particular
lighting conditions, it may be possible for a user to discern
features of the conductive micropattern. For example, conductive
micropattern elements may be rendered less visible by reducing
their width to less than 10 micrometers, but they may still produce
moire patterns due to optical interference with the regular spacing
of display pixels from, for example, a liquid crystal display (LCD)
or an organic light emitting diode (OLED) display.
[0189] In some embodiments, the micropattern may have pseudo-random
variations. The term pseudo-random describes variation in the
micropattern from an otherwise regular geometry. Regular geometries
include straight lines in the case of one dimensional conductor
elements and arrays of pattern features having translational
symmetry on a short length scale (for example, on the scale of one
to two cells) in the case of two dimensional conductor elements
(for example, meshes). Pseudo-random variation refers to the
non-regular perturbation of one dimensional or two dimensional
conductor elements. Thus, pseudo-random one dimensional conductor
elements are not straight lines, but rather they deviate from
straightness in a way that, on at least some length scale, is not
periodic. Pseudo-random two dimensional conductor elements are not
meshes composed of a single cell geometry or a small number of cell
geometries (for example, two or four) that repeat regularly in two
dimensions, but rather they include many cells in proximity (for
example, greater than 10 or greater than 100) that vary in shape.
The term random as used herein refers to such a lack of regularity
as just described, and may be the result of i) a process that
yields truly random micropattern geometry (that is, the geometry
varies in random fashion from one article to the next), or ii) a
process that yields a defined geometry that is the same from one
article to the next, but that deviates intentionally from
regularity. The latter of these two descriptions relates to
pseudo-random variation.
[0190] FIG. 30 shows a magnified view of pixels 58 with straight
microconductor 61 and, a first randomly curved micro-conductor 63,
and a second randomly curved microconductor 62. Also shown is LCD
mask line 59. Microconductor 61 will cause visible interference
with the display pixels, because it blocks one color over a
significant distance, and its near but imperfect alignment with the
vertical columns of pixel elements in the LCD may cause visible
interference. Micro-conductor 63 is generally less noticeable than
micro-conductor 61 because it bends pseudo-randomly to obscure
different colors of pixels in a vertical row. Microconductor 62
bends pseudo-randomly so it does not align with display pixels. The
period (length) of bends ensures that, on average, line 62 will
cross from one pixel to another or from one pixel color to another
within a few pixels distance, avoiding visually apparent patterns.
Bends in line 63 are larger in amplitude so line 63 intersects
several parallel rows of pixels.
[0191] Another method of reducing the visibility of the conductive
micropattern elements is to place them behind (relative to a viewer
of the display) some type of a substrate or coating having one or
more features that obscure or reduce the visibility of the
micropattern or microconductors. This technique could be used on
its own or in combination with the techniques described above
regarding random changes in the microconductor's path.
[0192] FIG. 31 illustrates a micropattern obscuring feature 267
positioned between a finger 85 (or viewer) and a micropatterned
microconductor 269. Finger 85 is shown capacitively coupling to the
micropatterened microconductor 269. Micropattern obscuring feature
267 could be a coating, or an additional substrate. The various
elements shown in FIG. 31 may be contained on separate substrates,
or they could merely be layers on a single substrate. It could be
part of substrate 268 (which includes micropatterned microconductor
269); it will preferably be positioned between the user or viewer
and the micropatterened microconductor. There may be one or more
additional layers (such as adhesive layers) or substrates between
the micropattern obsscuring feature 267 and the micropatterned
microconductor. Display 270 is positioned below substrate 268.
There may be one or more layers or substrates between substrate 268
and display 270. Display 270 may be any display upon which a touch
sensing device may be affixed, such as for example an LCD display
or an OLED display. FIG. 31 shows only one exemplary configuration
of how a micropattern obscuring feature may be employed to reduce
the visibility of a microconductor. Depending on the type of
display (for example a rear projection display), the micropattern
obscuring feature may be modified accordingly, mutatis
mutandis.
[0193] In one embodiment, micropattern obscuring feature 267 is an
anti-glare surface. An anti-glare (AG, or matte) finish on the
surface over a display is often used to scatter reflected light,
making the displayed light (from display 270) more viewable. An
anti-glare surface has the side effect of scattering the light from
the display also, so resolution of displayed images is in some
embodiments reduced. An anti-glare surface is generally made by
forming random surface structures (for example, bumps) on the
outer-most surface over a display, either by etching the surface or
by coating it with a material that forms surface structures of
transparent material. Each surface structure acts as a lens or
facet, depending on the shape of the structure, so any optical
feature under a surface structure will be diffracted in a random
direction.
[0194] The degree of display resolution reduction from an
anti-glare finish may be mitigated by minimizing the size of
surface structures to be significantly less than the dimensions of
display pixel elements. Typical anti-glare surface structures have
randomly or pseudo-randomly varying shapes with dimensions
averaging 10 .mu.m to 20 .mu.m (see, for example, US patent
application 2006/0046078.) Such structures may then be less than
10% of the size of a typical LCD display pixel, but would be larger
than the width of typical conductive micropattern element as
described herein, so an anti-glare surface can, in some
embodiments, render conductive micropattern elements
(microconductors) un-resolvable by the human eye, while minimally
affecting a displayed image. Common tests for display resolution
include the USAF 1951 resolution target and the EIA 1956 video
resolution target, both of which comprise sets of fine parallel
lines of various width and pitch. The minimum resolvable pitch
(lines/meter) is a measure of resolution. By these measurements, 1
.mu.m to 10 .mu.m microconductors will be un-resolvable behind many
anti-glare surfaces commonly used for displays, especially when the
microconductors' line spacing is randomized as in FIG. 30, and
spacing is much further apart than the standard test methods cited
above.
[0195] Generally, anti-glare surface structures should be in the
range of 20% to 200% of the visible cross section of the
microconductors. This is easy to achieve with printed
microconductors discussed herein, and it can also be achieved with
10 .mu.m to 25 .mu.m diameter micro-wire electrodes described in,
for example, U.S. Pat. No. 6,137,427 (Binstead).
[0196] Some display technologies, for example rear projection
displays (and front projection displays), may project through or
onto a surface that has light diffusing properties. A diffusing
surface is similar to an AG surface in that it scatters light, but
it is translucent with a higher haze value. The properties of these
surfaces may be similar to AG surfaces discussed above, including
the relative sizes of typical surface structures. So,
microconductor sensor electrodes embedded in a rear projection
display may also be optically obscured by the AG surface and/or
diffusing properties of a surface or substrate.
[0197] In another embodiment, micropattern obscuring feature 267 is
a polarizer or contrast-enhancing filter. Microconductors overlaid
on a display have possible optical effects including reduction of
light transmission, moire patterns, and reflection of ambient
light. Reflection can be reduced by placing a touch sensor behind
the front polarizer of an LCD. See, for example, U.S. Pat. No.
6,395,863 (Geaghan). For example, a microconductor-based matrix
capacitive touch screen or magnetic digitizer (constructed on a
birefringent substrate such as cast polycarbonate) may be laminated
under the front polarizer of an LCD. Most polarizers are made of
laminated layers, (for example, iodine doped polyvinylalcohol (PVA)
sandwiched between two sheets of TAC (cellulose triacetate)).
Electrodes of a microconductor based capacitive touch screen or
magnetic digitizer can be printed directly onto one or more of the
layers of a polarizer prior to laminating the polarizer sheets
together. A hardcoat barrier coat may be applied to TAC prior to
printing of microconductors. A sensor including the microconductor
electrodes may be placed behind a contrast enhancement filter, (for
example, 40% gray filter) to reduce the optical effect of reflected
light from microconductors.
[0198] To minimize interference with the pixel pattern of the
display and to avoid view ability of the pattern elements (for
example, conductor lines) by the naked eye of a user or viewer, the
minimum dimension of the conductive pattern elements (for example,
the width of a line or conductive trace) should be less than or
equal to approximately 50 micrometers, or less than or equal to
approximately 25 micrometers, or less than or equal to
approximately 10 micrometers, or less than or equal to
approximately 5 micrometers, or less than or equal to approximately
4 micrometers, or less than or equal to approximately 3
micrometers, or less than or equal to approximately 2 micrometers,
or less than or equal to approximately 1 micrometer, or less than
or equal to approximately 0.5 micrometer.
[0199] In some embodiments, the minimum dimension of conductive
pattern elements is between 0.5 and 50 micrometers, in other
embodiments between 0.5 and 25 micrometers, in other embodiments
between 1 and 10 micrometers, in other embodiments between 1 and 5
micrometers, in other embodiments between 1 and 4 micrometers, in
other embodiments between 1 and 3 micrometers, in other embodiments
between 0.5 and 3 micrometers, and in other embodiments between 0.5
and 2 micrometers. With respect to the reproducible achievement of
useful optical properties (for example high transmission and
invisibility of conductive pattern elements with the naked eye) and
electrical properties, and in light of the constraint of using
practical manufacturing methods, preferred values of minimum
dimension of conductive pattern elements are between 0.5 and 5
micrometers, more preferably between 1 and 4 micrometers, and most
preferably between 1 and 3 micrometers.
[0200] In general, the deposited electrically conductive material
reduces the light transmission of the touch sensor, undesirably.
Basically, wherever there is electrically conductive material
deposited, the display is shadowed in terms of its viewability by a
user. The degree of attenuation caused by the conductor material is
proportional to the area fraction of the sensor or region of the
sensor that is covered by conductor, within the conductor
micropattern.
[0201] One skilled in the art will appreciate that the present
invention can be practiced with embodiments other than those
disclosed. The disclosed embodiments are presented for purposes of
illustration and not limitation, and the present invention is
limited only by the claims that follow.
* * * * *